Continuous gas analysis

Transcription

1 Oxygen analyzer for standard applications 7MB2001 Operating instructions Continuous gas analysis

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3 General information 1 Description 2 Continuous gas analysis Oxygen analyzer for standard applications Operating Instructions Mounting and connecting 3 Commissioning 4 Operation 5 Maintenance and servicing 6 Spare parts list 7 Technical specifications 8 Dimension drawings 9 Appendix ESD Directives List of abbreviations/acronyms A B C 7MB /2011 A5E

4 Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the relevant information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed. Trademarks All names identified by are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Industry Sector Postfach NÜRNBERG GERMANY Order number: A5E P 02/2012 Technical data subject to change Copyright Siemens AG 2001, All rights reserved

5 Table of contents 1 General information Device model and validity Information for our customers General information Special information and warnings Proper use Qualified Personnel Notes on warranty Delivery information Standards and regulations Description Area of application Design Communication interface Principle of operation Mounting and connecting Safety instructions Installation requirements Connections Gas connections and internal gas flow diagram Sample gas line Reference gas line Pressure sensor Gas preparation Gas flow diagram Electrical connections Mains connection Connection of the signal cables Pin assignments Example of AUTOCAL connection...29 Operating Instructions, 12/2011, A5E

6 Table of contents 4 Commissioning Safety instructions Preparation for commissioning General information Selection of the reference gas Initial commissioning Calibration examples Operation General information Measured value display and control panel Device operating modes Editing inputs Operating sequence Introduction to the main menu Entering a submenu Returning to display mode Fast function selection Overview of operating functions Analyzer status Analyzer configuration (function 1) Diagnostic values (function 2) Logbook (function 3) Display measuring ranges (function 4) Calibration Calibration of the zero point (function 20) Span calibration (function 21) Zero/span setpoints (function 22) Calibration setting (function 23) AUTOCAL (function 24) Drift values (function 25) Measuring ranges Select measuring ranges (function 40) Define measuring ranges (function 41) Parameters Electric time constants (function 50) Limits (function 51) On/off functions (function 52) Status messages (function 53) Graphical representation of measured values (function 54) Measured value display (function 55) LCD contrast (function 56) Magnetic field frequency (function 57) Date/time (function 58) Measuring point switching (function 59) Logbook settings (function 60) Operating Instructions, 12/2011, A5E

7 Table of contents 5.6 Configuration Analog output (function 70) Relay outputs (function 71) Binary inputs (function 72) ELAN configuration (function 73) Reset (function 74) Save, load data (function 75) Suppression of short noise signals (function 76) Measured value memory (function 77) Calibration tolerances (function 78) Change codes (function 79) Device test (function 80) Language selection (function 81) Pressure correction (function 82) Correction of cross-interference (function 83) Phase adjustment (function 84) Switch valves (function 85) Linear temperature compensation (function 86) Error on/off (function 87) PROFIBUS configuration (function 90) Maintenance and servicing Safety instructions Analyzer section Design of the analyzer section Disassembling the analyzer section Removing the sample gas restrictor Replacement of motherboard and add-on board Replacing fuses Cleaning the device Maintenance requests and fault messages Maintenance requests Faults Spare parts list General information Analyzer section Electronics Gas channel Operating Instructions, 12/2011, A5E

8 Table of contents 8 Technical specifications General technical specifications Reference gases Zero point error Materials used in the sample gas channel Dimension drawings Dimension drawings A Appendix A.1 EC Declaration of Conformity A.2 Return delivery B ESD Directives B.1 ESD guidelines C List of abbreviations/acronyms C.1 List of abbreviations Glossary Index Operating Instructions, 12/2011, A5E

9 General information Device model and validity You have purchased the, a device that that undergoes continuous development and therefore can vary in functionality and software release in comparison to other devices of the same type. This manual describes the gas analyzer with the software release Information for our customers Before beginning work with this device, please read this manual! It contains important information and data whose observation ensures proper device function and saves you servicing costs. The manual will help you to operate the device more easily and efficiently, allowing you to achieve reliable results. 1.3 General information This device left the factory in a safe and proper condition and has been tested. In order to maintain this condition and to ensure safe operation of this product, it should only be used in the manner described by the manufacturer. Furthermore, proper transportation, storage, installation, operation and maintenance of the device are vital for ensuring correct and safe operation. This manual contains the information required for the intended use of the described product. It is addressed to technically qualified personnel who are specially trained or who have the relevant knowledge of automation technology (measuring and control systems). Knowledge and technically correct implementation of the safety notes and warnings contained in this manual are required for safe installation and commissioning, as well as for safety during the operation and maintenance of the described product. Only qualified personnel have the required professional knowledge for correctly interpreting the generally valid safety notes and warnings in this manual in each specific case and to act accordingly. This manual is an inherent part of the scope of delivery, despite the fact that it can be ordered separately for logistic reasons. Operating Instructions, 12/2011, A5E

10 General information 1.4 Special information and warnings Due to the variety of technical details, it is not possible to consider every single detail for all versions of the described product and for every conceivable case in the set-up, operation, maintenance and use in systems. For further information, or in the case of problems which are not covered in enough detail in this document, please request the required information from your local or responsible Siemens regional office. Note In particular, before using the device for new research and development applications, we recommend that you first contact us to discuss the application in question. 1.4 Special information and warnings This manual provides you with information on using, installing, operating, and maintaining the device. Pay particular attention to all special information and warnings. Information of this type is set apart from the rest of the text and is marked with the corresponding pictograms. This information provides you with useful tips and helps avoid maloperations. 8 Operating Instructions, 12/2011, A5E

11 General information 1.5 Proper use 1.5 Proper use Proper use within the context of this manual, means that the product may be used only for the applications described in the catalog or the technical description, and only in combination with the equipment, components and devices of other manufacturers recommended or permitted by Siemens. The product described in this manual has been developed manufactured, tested and documented in compliance with relevant safety standards. When the handling rules described for the configuration, installation, proper operation and maintenance, as well at the safety guidelines are adhered to, therefore, there is normally no risk to the health of persons or in respect to damage to property. This device was designed to ensure safe isolation of the primary and secondary circuits. Low voltages that are connected must therefore also be generated with safe isolation. WARNING Dangerous contact voltage After removing the housing or protection against direct contact or after opening the system cabinet, certain parts of of this device/system will be exposed that can carry hazardous voltage. Therefore, only appropriately qualified persons are permitted to perform work within this device. These persons must be thoroughly familiar with all sources of danger and service activities in accordance with these operating instructions. 1.6 Qualified Personnel Qualified personnel are people who are familiar with the installation, mounting, commissioning, and operation of the product. These people have the following qualifications: They are authorized, trained or instructed in operating and maintaining devices and systems according to the safety regulations for electrical circuits, high pressures and aggressive as well as hazardous media. For explosion-proof devices: they are authorized, trained, or instructed in carrying out work on electrical circuits for hazardous systems. They are trained or instructed in maintenance and use of appropriate safety equipment according to the safety regulations. Operating Instructions, 12/2011, A5E

12 General information 1.7 Notes on warranty 1.7 Notes on warranty The contents of this manual shall not become part of or modify any prior or existing agreement, commitment or legal relationship. The sales contract contains all obligations on the part of Siemens as well as the complete and solely applicable warranty conditions. Any statements regarding device versions described in the manual do not create new warranties or modify the existing warranty. The content reflects the technical status at the time of publishing. Siemens reserves the right to make technical changes in the course of further development. 1.8 Delivery information The respective scope of delivery is listed on the shipping documents enclosed with the delivery in accordance with the valid sales contract. When opening the packaging, please observe the corresponding information on the packaging material. Check the delivery for completeness and undamaged condition. In particular, you should compare the Order No. on the rating plates with the ordering data, if available. If possible, please retain the packaging material, since you can use it again in case of return deliveries. 1.9 Standards and regulations As far as possible, the harmonized European standards were the basis for the specification and production of this device. If no harmonized European standards have been applied, the standards and regulations for the Federal Republic of Germany are valid. When this product is used beyond the scope of these standards and regulations, the valid standards and regulations of the country of the operating company apply. 10 Operating Instructions, 12/2011, A5E

13 Description Description Area of application The gas analyzers use a measuring principle based on the paramagnetic alternating pressure method and are used to measure oxygen in gases. NOTICE The is not suited for measuring flammable, toxic and corrosive gases. Application examples Measurement of oxygen For boiler control in incineration plants For quality monitoring in ultra-pure gas For environmental protection For monitoring of process exhaust gas For process optimization Operating Instructions, 12/2011, A5E

14 Description 2.1 Area of application Important features Four freely configurable measuring ranges, also with suppressed zero point, all measuring ranges are linear Electrically isolated measured value output 0/2/4 to 20 ma Selectable automatic or manual measuring range switching; remote switching is also possible Measured values can be stored during calibration Wide range of selectable time constants (static/dynamic noise suppression); i.e. the response time of the device can be adapted to the respective measuring task Simple handling through menu-guided operation according to NAMUR recommendation Fast response time Low long-term drift Reference gas supply either externally (N2, O2 or air, approx to 4000 hpa via sample gas pressure) or via built-in reference gas pump (ambient air) Two control levels with separate authorization codes to prevent unintentional and unauthorized operator intervention External pressure sensor can be connected for correction of variations in the process gas pressure in the range 800 to 1200 hpa (absolute) Automatic measuring range calibration can be configured Fieldbus connection (optional) Monitoring of sample gas (optional) Monitoring of reference gas (only with version with internal reference gas pump) Variety of narrow measuring ranges, depending on version 2.0 % or 5.0 % O2 Easy device replacement since electric connections can be simply disconnected from the device 19" rack unit with 4 height units (U) for installation in swivel frame 19" rack unit with 4 U for installation in cabinets, with or without telescopic rails Front plate can be swung down for servicing purposes (laptop connection) Internal gas channels: Hose made of FKM (Viton) Connections for sample gas: Pipe diameter 6 mm or 1/4" Sample chamber of stainless steel (mat. no ) 12 Operating Instructions, 12/2011, A5E

15 Description 2.2 Design 2.2 Design Display and control panel Large LCD for simultaneous display of: Measured value (digital and analog displays) Status line Measuring ranges Contrast of the LCD adjustable via the menu Permanent backlighting with LED 5-digit measured value display (decimal point counts as digit) Washable membrane keyboard/front panel Menu-guided operation for parameter assignment, configuration and calibration Operating help in plain text Graphic display of concentration trend; programmable time intervals Inputs and outputs Two analog inputs configurable (e.g. interference correction or external pressure sensor) Six relay outputs, freely configurable (e.g. faults, maintenance request, calibration, limit alarm, external solenoid valves) Six digital inputs, freely configurable (e.g. for measurement range switchover, processing of external signals from sample preparation) Can be extended by eight additional digital inputs and eight additional relay outputs for automatic calibration with max. four calibration gases Communication RS485 (standard) Optionally available: AK interface for the automotive industry with extended functions Converter for RS232, USB and Ethernet Integration in networks via PROFIBUS DP/PA interface SIPROM GA software as the service and maintenance tool Operating Instructions, 12/2011, A5E

16 Description 2.2 Design SIEMENS CAL CTRL CODE 1O.5O % vol O 2 O / CLEAR ESC INFO O ENTER MEAS 1 Status line for display of analyzer state (configurable) 2 Two code levels according to NAMUR (maintenance and specialist levels) 3 Display of activated measuring ranges 4 Five softkeys for menu control 5 ESC key for returning to previous input step, with application of any changes made 6 INFO key for help functions for the current menu 7 MEAS key for returning to measuring mode 8 CLEAR key to delete numerical inputs 9 ENTER key to accept numerical values 10 Numerical keypad for entering numerical values 11 Display of start-of-scale and full-scale values 12 Display of concentrations as digits and bars Figure 2-1 Membrane keyboard and graphic display 14 Operating Instructions, 12/2011, A5E

17 Description 2.3 Communication interface 2.3 Communication interface Figure 2-2 Various analyzers, networked with 485 Operating Instructions, 12/2011, A5E

18 Description 2.4 Principle of operation 2.4 Principle of operation 1 Reference gas channel 2 Restrictors 3 Reference gas channels 4 Microflow sensor for measured signal 5 Sample gas inlet 6 Sample chamber 7 Paramagnetic measurement effect 8 Electromagnet with alternating field strength 9 Sample gas and reference gas outlet ΔP O 2 O 2 O 2 O 2 O 2, principle of operation In contrast to almost all other gases, oxygen is paramagnetic. This property is utilized as a measuring effect by the channel. Due to their paramagnetism, oxygen molecules in an inhomogeneous magnetic field always move in the direction of increased field strength. When two gases with different oxygen contents meet in a magnetic field, a pressure difference is produced between them. In the case of, one gas (1) is a reference gas (N2, O2 or air), the other is the sample gas (5). The reference gas is introduced into the sample chamber (6) through two channels (3). One of these reference gas streams meets the sample gas within the area of a magnetic field (7). Because the two channels are connected, the generated pressure difference creates a flow. This flow is converted into an electric signal by a microflow sensor (4). The pressure difference is proportional to the difference in the oxygen content of sample and reference gas. The microflow sensor consists of two nickel-plated grids, which are heated to approximately 120 C. Together with two supplementary resistors they form a Wheatstone bridge. The pulsating flow results in a change in the resistance of the Ni grids. This leads to an offset in the bridge which is proportional to the oxygen content of the sample gas. Because the microflow sensor is located in the reference gas stream, the measurement is not influenced by the thermal conductivity, the specific heat or the internal friction of the sample gas. This also provides a high degree of corrosion resistance because the microflow sensor is not exposed to the direct influence of the sample gas. A magnetic field with alternating strength (8) prevents detection of the background flow in the microflow sensor, enabling measurement to be performed independent of the sample chamber position and thus also independent of the location where the gas analyzer is used. The sample chamber is directly in the sample channel and has a small volume, and the microflow sensor is a low-lag sensor. This results in a very fast response time for the. 16 Operating Instructions, 12/2011, A5E

19 Mounting and connecting Mounting and connecting Safety instructions DANGER Explosion hazard The analyzer must not be operated in potentially explosive atmospheres. The supply of gases with combustible components in concentrations above the lower explosive limit (LEL) must be clarified in consultation with the relevant hazard experts and is ultimately the responsibility of the operator. WARNING Dangerous contact voltage Certain parts of this device are under dangerous voltage. In order to avoid contact with live parts, the housing must be closed and grounded upon completion of all assembly and installation work. Failure to comply with this can result in death, personal injury and/or damage to property. WARNING Release of hazardous gases Gases may be released if there are leaks in the sample gas channel. For this reason, toxic and corrosive gases are not allowed to be be measured with this device. Failure to comply with this can result in death, personal injury as well as damage to property and the environment. CAUTION Incorrect mounting The device can be damaged, destroyed or its functionality impaired through improper mounting. Before installing ensure there is no visible damage present on the device. Make sure that process connectors are clean, and suitable gaskets and glands are used. Mount the device using suitable tools. Refer to the information in "Technical data", for example installation torques requirements. Operating Instructions, 12/2011, A5E

20 Mounting and connecting 3.2 Installation requirements 3.2 Installation requirements Vibration Select an installation location which is as vibration-free as possible. If you install the device in a cabinet or in desktop housing, you must hang it on support rails. It is not sufficient to only secure the front side, since the intrinsic weight of the device creates too much load on the chassis. Temperature Ensure sufficient ventilation between the devices if you install them in control cabinets. If the device is installed outdoors, it must be protected from direct sunlight. Ensure that the permissible ambient temperature range of 5 to 45 C is maintained during operation (see Technical Specification section). Magnetic fields Magnetically sensitive devices should not be installed in close proximity of since it is inherently emits stray magnetic fields. Depending on the sensitivity, distances up to 50 cm are required (see also Function 57). 18 Operating Instructions, 12/2011, A5E

21 Mounting and connecting 3.3 Connections 3.3 Connections Figure 3-1 Back side with gas and electrical connections Operating Instructions, 12/2011, A5E

22 Mounting and connecting 3.3 Connections Gas connections and internal gas flow diagram Sample gas line Connector stems with a pipe diameter of 6 mm or 1/4" are provided for gas connections. For the gas supply and discharge from the device, you need to select a suitable material for the sample gas. CAUTION Dynamic pressure in the sample gas channel The device must be operated in such a way that the sample gas pressure in the analyzer does not accumulate. When several devices are connected in series, you must ensure that there are no restrictions in the gas channels of the downstream devices (free exhaust gas flow). You must remove any sample gas restrictors installed in the device. The only restrictor that can be retained is one between the sample gas line and the first gas analyzer unit. After removing the sample gas restrictors, the sample gas monitoring (pressure switches) of the downstream analyzers will be inoperable. To avoid error messages, you must have disable the corresponding error messages ("Gas flow rate is too low") in the configuration function of the software (section , Function 87 (Page 101), Error S16). You should also note in this case that the assignment of a relay to the "Sample gas flow" error message has no function. If the sample gas flows to an exhaust gas line, you must note the following: The flow resistance in the exhaust gas line should be kept as low as possible with a line as short as possible or with a large diameter junction. The exhaust gas line must be free of rapid pressure fluctuations. If this is not the case, either a special exhaust gas line must be installed, or a damping vessel (> 1 l) with restrictor must be installed between the device and exhaust gas line (pneumatic low pass). 20 Operating Instructions, 12/2011, A5E

23 Mounting and connecting 3.3 Connections Reference gas line The connection stems for the reference gas has a pipe diameter of 6 mm or 1/4". The reference gas line must be as short as possible and have a small cross-section. If you use N2 or O2 as a reference gas, you must use a metal pipe as the supply line. If air is used as the reference gas, it is recommended to install a dryer attachment in the intake to avoid volume errors in comparison to the gas side that can be caused by air humidity. If you subsequently convert the device to a different reference gas supply, ensure that only trained service personnel perform the replacement work for the connector stems and the reference gas restrictor Pressure sensor The device has an internal pressure sensor for correcting the effect of pressure on the measured value. It is firmly mounted in the analyzer unit and directly measures sample gas pressure through the reference gas supply. The pressure sensor is therefore not involved in the installation Gas preparation To prevent contamination of parts from contact with the sample gas, which can thus influence the measurement, the sample gas must be sufficiently prepared before it is introduced in the device. The following components are usually located upstream from the sample gas inlet of the device: Gas sampling device Sample gas cooler Filter A gas suction pump Depending on the composition of the sample gas, you may need additional equipment such as a wash bottle, additional filters and pressure reducers. Also provide for the removal of corrosive components or components that interfere with the measurement process by using appropriate absorption filters. Operating Instructions, 12/2011, A5E

24 Mounting and connecting 3.3 Connections Figure 3-2 Example of gas preparation Gas flow diagram 1 Figure 3-3 Gas path with installed reference gas pump 22 Operating Instructions, 12/2011, A5E

25 Mounting and connecting 3.3 Connections F 14 7 P P Figure 3-4 gas channel, with reference gas connection to hpa absolute Key for gas flow diagrams 1 Sample gas inlet 9 Purging gas 2 Sample gas outlet 10 Restrictor in reference gas channel (outlet) 3 n.c. 11 Pressure switch for reference gas monitoring 4 Reference gas inlet 12 Pump 5 Restrictor in reference gas channel 13 Filter 6 Analyzer section 14 Flow indicator in sample gas channel (optional) 7 Restrictor in sample gas channel 15 Pressure sensor 8 Pressure switch in sample gas channel (option) Operating Instructions, 12/2011, A5E

26 Mounting and connecting 3.3 Connections Electrical connections Mains connection WARNING Dangerous contact voltage Danger of electric shock in case of incorrect connection. For the electrical connection specifications, refer to the information in Chapter "Technical specifications (Page 123)". At the mounting location of the device observe the applicable directives and laws for installation of electrical power installations with rated voltages below 1000 V. The device comes with an appliance plug which may only be connected to the mains supply line by qualified personnel. The mains supply line must comply with the valid regulations and conditions for the place of installation and be provided with a protective conductor which lies at the potential of the enclosure. The cross-section of each wire must be 1 mm². Connect the phase conductor to the marked position in the plug. Install the mains line separately from the signal lines. Provide a mains disconnection device in the direct vicinity of the device (for load rating, see rating plate). It must be readily accessible and marked. Check whether the existing mains voltage agrees with the mains voltage specified on the rating plate. 24 Operating Instructions, 12/2011, A5E

27 Mounting and connecting 3.3 Connections Connection of the signal cables WARNING Inadequate signal lines If signals (e.g. 4 to 20 ma analog output) are to be introduced into a hazardous area of zone 1, they must be intrinsically-safe. Additional upgrading or retrofitting of the device with energy-limiting modules is also required in this case. Failure to comply with this can result in death, serious personal injury and/or damage to property. The Ex marking of these energy-limiting modules must be clearly visibly on the device. WARNING Only connect the signal lines to devices which have reliable electric isolation from their power supply. The connection lines to the relay outputs, the digital inputs, the analog inputs and the analog outputs must be shielded. The reference ground of the analog inputs is the potential of the housing. The analog output is floating. Operating Instructions, 12/2011, A5E

28 Mounting and connecting 3.3 Connections As a measure to suppress sparking across the relay contacts (e.g. limit relays), RC elements must be connected as shown in the following figure. Note that the RC element results in a drop-out delay for an inductive component (e.g. solenoid valve). The RC element should be sized according to the following rule of thumb: R [ Ω ] 0.2 x RL [ Ω]; C[ μf ] IL [ A ] You must also use a non-polarized capacitor for the RC element. Figure 3-5 Example of spark suppression on a relay contact When operated with direct current, a spark suppression diode can be installed instead of the RC element. Connect the signal lines to the SUB-D plug connectors at the rear of the device. Refer to the ELAN interface description (Order No. C79000-B5200-C176 German, C79000-B5276-C176 English) for details on the interface cable. 26 Operating Instructions, 12/2011, A5E

29 Mounting and connecting 3.3 Connections Pin assignments Figure 3-6 Motherboard pin assignments Operating Instructions, 12/2011, A5E

30 Mounting and connecting 3.3 Connections Figure 3-7 Pin assignments of the add-on board 28 Operating Instructions, 12/2011, A5E

31 Mounting and connecting 3.4 Example of AUTOCAL connection 3.4 Example of AUTOCAL connection Figure 3-8 Connector pin assignment and valve diagram of an AUTOCAL connection Operating Instructions, 12/2011, A5E

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33 Commissioning Safety instructions DANGER Explosion hazard The analyzer must not be operated in potentially explosive atmospheres. The supply of gases with combustible components in concentrations above the lower explosive limit (LEL) must be clarified in consultation with the relevant hazard experts and is ultimately the responsibility of the operator. WARNING Dangerous contact voltage Certain parts of this device are under dangerous voltage. In order to avoid contact with live parts, the housing must be closed and grounded upon completion of all assembly and installation work. Failure to comply with this can result in death, personal injury and/or damage to property. WARNING Release of hazardous gases Gases may be released if there are leaks in the sample gas channel. For this reason, toxic and corrosive gases are not allowed to be be measured with this device. Failure to comply with this can result in death, personal injury as well as damage to property and the environment. Operating Instructions, 12/2011, A5E

34 Commissioning 4.2 Preparation for commissioning 4.2 Preparation for commissioning General information Gas preparation Make all devices in the gas channel upstream from the analyzer ready for operation (e.g.: gas sampling devices, gas cooling device, condensate vessels, filters and any connected controllers, recorders or indicators. Read carefully the instructions and information in the operation manuals of the devices! Operation Before switching on the device, familiarize yourself with its operation (see section 5 of this manual)! Interfaces Make sure that all interfaces are properly assigned and configured. Electrical connections Make sure that all electrical connections have been correctly made. Read also the information in the "Electric connection" section. 32 Operating Instructions, 12/2011, A5E

35 Commissioning 4.2 Preparation for commissioning Selection of the reference gas When you select the reference gas, you must ensure that the various measurement spans have at least one common point. This point is then defined as 'physical zero point'. This applies to all measuring ranges. Once this point is known, the reference gas can be selected. This is explained by the following example: There are four measuring ranges: % O % O % O % O2 These four measurement ranged have the spans from 17 to 22 % O2 in common. The physical zero point should lie within this range. Air (20.95 % O2%) is suitable as the reference gas in this case. An exception to this principle is possible if the smallest measuring span 5 % O2 and the distance to the reference gas is not more than 20 % O2. Then, the physical zero point may be located outside the measuring range. In this case, however, the pressure correction (see Function 82 in section 5) must be activated, since there a pressure relationship due to the large zero point offset. The purity of the reference gas has to be appropriate for the measuring task. Installing the reference gas connection The reference gas connection is made depending on the order: Air (low pressure variant) Air as the reference gas is sucked in with the internal pump. When the analyzer is mounted in a cabinet, you must therefore ensure that the air sucked in is supplied from outside the cabinet. Nitrogen, oxygen, air (high pressure variant) Pay attention to the purity of the gas (4.6)! The supply is here comes from a compressed gas cylinder with a pressure setting of 2000 to 4000 hpa over the sample gas pressure. A sintered metal frit (porous filter) is in the coupling to prevent entry of dirt particles into the analyzer. Operating Instructions, 12/2011, A5E

36 Commissioning 4.2 Preparation for commissioning Introducing reference gas Always introduce the reference gas before beginning the measurements. Reference gas should always continue to flow even if the measurements are temporarily interrupted. The increased consumption caused by this is negligible when compared to reference gas line is sealed. Compressed gas cylinder If the reference gas is taken from a compressed gas cylinder, the reference gas line must be purged prior to commissioning. You must then check the line for leaks, because leakage losses are often greater than the reference gas consumption. To do this, close the valve at the compressed gas cylinder. If the pressure indicator at the reducer value of the gas cylinder does not drop by more than 1000 hpa/min, the gas connection is sufficiently sealed. The reference gas pressure must always be 2000 hpa or more above the sample gas pressure. Checking the reference gas flow To do this, proceed as follows: 1. Close the sample gas inlet couplings. 2. Lay a hose with an internal diameter of 4 mm from the sample gas outlet nozzle into a beaker filled with water. 3. Observe the glass. The reference gas must be slow with 1 to 2 bubbles per second coming through the water. Checking for leaks in the sample gas channel with hosed devices To do this, proceed as follows: 1. Close the reference gas connection. 2. Establish a pressure of approx. 100 hpa in the sample gas channel. 3. Wait about 1 minute. During this time, the inflowing sample gas will adapt to the ambient temperature. 4. Note the pressure. 5. Wait another 15 minutes. 6. Note the pressure again. The sample gas channel is sufficiently tight when the pressure has changed by no more than 1 hpa (1 mbar) within these 15 minutes. 34 Operating Instructions, 12/2011, A5E

37 Commissioning 4.2 Preparation for commissioning Initial commissioning Switch on the power supply After you have ensured that all connections have been made and there are no leaks, switch on the device. After a short period, the measured value display appears on the operator display. The status display is located above this in the top row (for details on the operator display see section 5.1). The measuring head is in the warm-up phase during the first five minutes. During this time, the display signals CTRL (function check). Setting the measuring span Specify the desired spans (measuring range full-scale value - measuring range start-of-scale value) with function 41. The start-of-scale or full-scale values are assigned to the 0(2/4) or 20 ma of the analog output. If you define multiple measurement ranges; we recommend that you set measurement range 1 for the smallest measuring span (MS)etc. In general, the following applies then: MS1 < MS2 < MS3 < MS4 Setting the physical zero point If the composition of test and reference gas are identical, their O2 difference is therefore zero and there is no measuring signal. We refer to this as the physical zero point. Depending on the reference gas, the physical zero point may therefore have any value between 0 and 100 % O2. The setpoint of the physical zero point is specified under function 22. Setting the setpoint of the sensitivity The setpoints of the sensitivity must be as far from the physical zero point as possible (at least 60 % of the respective measuring span). The setpoint or setpoints are entered with function 22. The calibration gases required for this must be made available for the adjustment. Selecting the calibration method Set the calibration mode to total or single calibration using either function 23 or 52. Single calibration means that each measuring range is calibrated using its own calibration gas. Total calibration means that you adjust one "leading measuring range" and all other measuring ranges are "tracked" to this using the switching ratio. When performing the calibration, ensure that the gas flows between 0.3 l/min and 1 l/min. Operating Instructions, 12/2011, A5E

38 Commissioning 4.2 Preparation for commissioning Calibrating the zero point The physical zero point is calibrated with function 20. It is applied to all configured measuring ranges. Calibrating sensitivity The sensitivity is calibrated with function 21. Compensating the effect of temperature The compensation of the temperature effect is stored permanently in the software (firmware) for the. No further actions are required for this. Noise suppression Noise in the measured signal can be suppressed using function 50. This function allows you to configure a low pass filter, which is assigned a time constant of maximum 100 s. 36 Operating Instructions, 12/2011, A5E

39 Commissioning 4.2 Preparation for commissioning Calibration examples The following examples reflect typical applications for the. O 2 monitoring in gases Measurement task: Measurement of oxygen in N2. Measuring range: 0 to 5 % O2; Reference gas: N2; Calibration gas: 4.7 % O2 Procedure Function Input Remarks no. Selection of measuring range start-of-scale value (2/4) ma Selection of measuring range full-scale value ma Specification of the setpoint for the physical zero point 22 0 Setpoint for physical zero point Specification of the setpoint for the sensitivity Setpoint for sensitivity Start zero point calibration 20 Introduce N2 Start sensitivity calibration 21 Introduce calibration gas Room air monitoring Measuring range: 15 to 21 % O2; Reference gas: Air (20.95 % O2); Calibration gas:15.3 % O2 Procedure Function Input Remarks no. Selection of measuring range start-of-scale value (2/4) ma Selection of measuring range full-scale value ma Specification of the setpoint for the physical zero point Setpoint for physical zero point Specification of the setpoint for the sensitivity Setpoint for sensitivity Start zero point calibration 20 Introduce air Start sensitivity calibration 21 Introduce calibration gas Operating Instructions, 12/2011, A5E

40 Commissioning 4.2 Preparation for commissioning O 2 measurement in flue gas Measuring range: 0 to 10 % O2; Reference gas: Air; Calibration gas: N2 NOTICE Reference gas out of range In this example, the O2 content of the reference gas is not within the measuring range of up to 10 % O2. Since the measuring span is greater than 5 %, however, an exception can be made in the selection of the reference gas. In this case, the pressure correction must be necessarily activated (see also Function 82 in section 5)! Procedure Function Input Remarks no. Selection of measuring range start-of-scale value (2/4) ma Selection of measuring range full-scale value ma Specification of the setpoint for the physical zero point Setpoint for physical zero point Specification of the setpoint for the sensitivity 22 0 Setpoint for sensitivity Start zero point calibration 20 Introduce air Start sensitivity calibration 21 Introduce N2 Purity monitoring of oxygen Measuring range: 95 to 100 % O2; Reference gas: Pure O2; Calibration gas: 95.6 % O2 Procedure Function Input Remarks no. Selection of measuring range start-of-scale value (2/4) ma Selection of measuring range full-scale value ma Specification of the setpoint for the physical zero point Setpoint for physical zero point Specification of the setpoint for the sensitivity Setpoint for sensitivity Start zero point calibration 20 Introduce pure O2 (100 %) Start sensitivity calibration 21 Introduce calibration gas Detailed operating instructions for performing all the required testing functions are provided in section 5 (Operation). 38 Operating Instructions, 12/2011, A5E

41 Operation Operation General information Measured value display and control panel SIEMENS CAL CTRL CODE % VOL O 2 O 1OO.O / CLEAR ESC INFO O ENTER MEAS 1 Status display 2 Display of dimension 3 Status line (can be programmed under function 53) 4 Display of measured component 5 Buttons with varying function (softkeys) 6 Display of activated measuring ranges with the current range marked 7 Limit marker on bargraph 8 Start-of-scale and full-scale values 9 Analog measured value display (bar chart, graph of the measured value with the start-of-scale and full-scale value of the current measuring range) 10 Measured value Figure 5-1 Measured value display and control panel Operating Instructions, 12/2011, A5E

42 Operation 5.1 General information Table 5-1 Button CLEAR ENTER ESC INFO MEAS Softkey Button meanings Meaning/function Clears the commenced number input Every number entered (except fast activation of a function) must be confirmed with [ENTER]. Jumps back one step in the operating structure. Changes are accepted without need for confirmation. Information about current menu / current function Jump back from every position in the operating structure to the "Decoded display mode" (you may be asked to confirm the entered data). Pressing the [MEAS] button again changes to "Coded display mode", i.e. another change in the "Operator control mode" requires the entry of the corresponding code. Varying function; possible here are: Submenu selection / function selection Selection of a subfunction ON/OFF switch function 40 Operating Instructions, 12/2011, A5E

43 Operation 5.1 General information Device operating modes Table 5-2 Device operating modes Mode Properties Remarks Coded display mode Measured value display is shown Protected submenus can only be reached by entering a code The current operating mode of the device (except for "Measure") is displayed in the bottom line Functional check not active Decoded display mode Measured value display is shown The submenus protected by the entered code are accessible The current operating mode of the device (except for "Measure") is displayed in the bottom line Functional check active Measured value can be influenced Operator control mode Menu or function is displayed Settings and inputs can be made Functional check active Measured value can be influenced The device only supplies reliable measured values in this mode, as far as it's in the "Measure" operating mode. From the operator control mode, you can reach this mode by pressing the [MEAS] button twice. From the operator control mode, you can reach this mode by pressing the [MEAS] button once and confirming or discarding the made entries. From "Coded display mode" you can reach this mode by entering the code of the corresponding operation level. In this mode, you can configure/calibrate the device. Operating Instructions, 12/2011, A5E

44 Operation 5.1 General information Schematic diagram of the operating sequence with operating modes MEAS ESC ESC ESC ESC CAL CTRL Code Main menu Functions menu Functions THC ppm C1 O O,O 1,O Diagnosis Calibration Measuring ranges Parameters Configuration MEAS Query (only following changes) Accept modifications? Yes No Figure 5-2 Operating sequence with operating modes 42 Operating Instructions, 12/2011, A5E

45 Operation 5.1 General information Editing inputs The values in the menus shown in this chapter are meant as examples. An active input field is shown with colons (e.g.: 10:) as a limiter. The cursor blinks under the number to be entered. By pressing the [ENTER] button, you finish your input and the value is stored. If there are several input fields on one function screen, the cursor positions itself at the next input field at the same time. Note Confirm every entered value, even the last of several values in a function, before exiting the function with [ENTER]! With the [CLEAR] button, you can clear a number which you have begun to enter. The cursor then jumps back to the first position of the input field. Graphic symbols = activated (ON state; also in status message in the status line) = deactivated (OFF state; also in status message in the status line) = access a submenu/subfunction = trigger a function/subfunction (e.g. Start calibration...) Operating sequence CAL CTRL CODE % Vol O 2 O.O 1OO.O Figure 5-3 Measured value display Operating Instructions, 12/2011, A5E

46 Operation 5.1 General information Introduction to the main menu The device must be in measuring mode. The right side of the display field shows the measured component, which is indicated with "MC" in the following illustrations of the display. A right arrow [ ] appears for it. This arrow indicates a softkey. The main menu can be opened by pressing this softkey. The main menu consists of the following commands (with the associated code level on the right): Function group Code level Analyzer status Not coded Calibration Code of code level 1 Measuring ranges Code of code level 1 Parameter Code of code level 1 Configuration Code of code level 2 The code of level 1 is factory set to "111", that of level 2 is factory set to "222". Main menu MC Analyzer status Calibration Measuring ranges Parameters Configuration 44 Operating Instructions, 12/2011, A5E

47 Operation 5.1 General information Entering a submenu If you select a submenu by pressing the associated softkey, the code of the corresponding operation level is queried once (exception: the submenu "Analyzer status" is freely accessible; selecting this does not change the operating mode). Decoding level 2 also decodes level 1. By entering a corresponding code, the device switches to the operator control mode, whereby the functional check is activated. The functional check "CTRL" (shown in the status line of the measured value display) is always activated by the device when an intervention endangers correct measurement, e.g. when the code is entered. If you have configured a corresponding relay using function 71 with "Functional check", an extra signal is sent out via the relay contact together with the decoding. This relay contact then signals every functional check activation, e.g. even the warm-up phases and calibration states of the device. Decoding also activates the measured value memory, providing you have configured this using function 77. The coding status of the device can be read in the status line of the measured value display as a symbol " CODE" for "coded" or " CODE" for "decoded". Operating Instructions, 12/2011, A5E

48 Operation 5.1 General information Returning to display mode You can use the [MEAS] key to jump back to "Decoded display mode" from any location in "Operator control mode". Any input started is aborted. Before jumping back, the following query appears: Return to meas. mode MC Accept modifications? YES NO Figure 5-4 Query before jumping back Press "YES" to accept changes permanently into the working memory of the parameter memory or "NO" to discard the changes. The device then changes to "Decoded display mode". By pressing the [ESC] brings you back to the most recent function screen. Changes are accepted here without a further query. Coding the device After jumping back to "Decoded display mode" with [ESC] or [MEAS], if you press [MEAS] again you put the device back into "Coded display mode". Only now is the function check once again deactivated and all states invoked by the decoding are released again Fast function selection In order to directly access the desired function when operating frequently from the "Coded display mode", a "Power user operation" was created. This allows you to directly access the desired function by entering the function number. This allows you to skip menu levels. However, the functions can only be directly called from the measured value display. For fast function selection, proceed as follows: 1. Enter the number of the desired function using the number keys. 2. Press the softkey of the component with the arrow. If the desired function is protected by a code, you will be asked to enter the code. 46 Operating Instructions, 12/2011, A5E

49 Operation 5.1 General information Overview of operating functions The following overview is a list of the device functions. This list corresponds to software version 4. Main menu item Function number Name of function Analyzer status Calibration (code 1) Measuring ranges (code 1) Parameters (code 1) Configuration (code 2) Factory data Diagnostics values Logbook Display measuring ranges Calibrate zero Calibrate span Zero/span setpoints Calibration settings (Total, Single) AUTOCAL Drift values Select measuring ranges Define measuring ranges Electric time constant Limits On/off functions Status signals Graphic measured-value display Measured-value display LCD contrast Magnetic field frequency Date/time Measuring-point switchover Logbook settings Analog output Relay assignment Digital inputs ELAN configuration Reset Save, load data Suppress short noise signals Measured value memory (analog output) Calibration tolerance Change codes Analyzer test Select language Pressure correction Correction of cross-interference Phase adjust Switch valves Linear temperature compensation Faults on/off PROFIBUS configuration Overview of operating functions Operating Instructions, 12/2011, A5E

50 Operation 5.2 Analyzer status 5.2 Analyzer status After selecting the diagnostic functions in the main menu by pressing the first (top) softkey ('Analyzer status'), the following menu screen appears with additional choices. Analyzer status MC Analyzer config. 2 Diagnostic values 3 Logbook 4 Display meas. ranges Figure 5-5 Analyzer status submenu The analyzer status functions are freely accessible. There is therefore no code query and no change in the operating mode. The analyzer status submenu offers you various functions for displaying device parameters and stored data Analyzer configuration (function 1) When this function is selected, important device manufacturing data can be viewed: Firmware No. Order No. of the software in the EPROM Order No. Information on device ordering data Production No. Indication of date of manufacture and device serial number Object version Indication of the hardware design of the device Software version and date Indication of the functional scope of the device 48 Operating Instructions, 12/2011, A5E

51 Operation 5.2 Analyzer status Diagnostic values (function 2) The most important diagnostic values may be called using function 2. They may allow conclusions to be drawn for evaluation of errors or setting work Logbook (function 3) In the logbook, all errors which led to a maintenance request (W) or a fault (S) are listed. The limit alarm (LIM) and functional check (CTRL) are also registered. However, these do not trigger a maintenance request or fault message. The logbook contains a max. of eight pages, with four messages per page. It works according to the cyclic buffer principle, i.e. when all eight pages (all 32 locations) are occupied, the oldest message is overwritten. You can delete or block logbook entries (function 60), but you can also switch them off individually (function 87). Note If an error occurs whose error message is switched off with function 87, there is no reaction at any configured interface. This applies to the ELAN interface, the analog output and the relay output Display measuring ranges (function 4) The measuring ranges defined using function 41 are listed here. However, you cannot carry out any changes in this function. Operating Instructions, 12/2011, A5E

52 Operation 5.3 Calibration 5.3 Calibration After selecting the calibration functions in the main menu by pressing the second softkey ('Calibration'), the following menu screen appears with additional choices. Calibration MC 2O Zero calibration 21 Span calibration 22 Setpoints total 23 Total/single cal. continue Figure 5-6 Calibration submenu This menu is protected by the code of code level 1. You can calibrate the device using the functions available in this menu. If the function you are looking for is not included in this overview, press the fifth softkey "...Continue" to go to other functions. The device allows you to perform calibration manually or automatically (function 24). The latter is only possible with an add-on board, which contains eight additional digital inputs and eight relay outputs. The setpoints for the zero and span calibrations are entered using function 22. The drift values are set with function 25, the single or total calibration with function 23. Following the selection of functions 20 and 21, the required gases must be introduced manually. 50 Operating Instructions, 12/2011, A5E

53 Operation 5.3 Calibration Calibration of the zero point (function 20) 2O Zero calib. MC Setpoint : O.OO % v/v Act. value: 15.6O % v/v Start calibration CANCEL Zero calibration In order to calibrate the zero, the device must be in the "Measure" operating mode. If this is not the case, calibration is not possible. The display will show the message "Analyzer is not measuring". The zero point is calibrated simultaneously for all measuring ranges, even when the span of the measuring ranges is calibrated individually. Only initiate calibration when the measured value (actual value) has stabilized after applying the zero gas. Otherwise, the calibration may be imprecise. If there is a lot of noise or the measured value is unstable over time, increase the time constant before calibrating (function 50). Operating Instructions, 12/2011, A5E

54 Operation 5.3 Calibration Span calibration (function 21) A single or total calibration is carried out depending on the setting made with function 23. This function is specific for the component. Single calibration ("Measure" operating mode required) 21 Span calib. MC Calibrate MR 1 Calibrate MR 2 Calibrate MR 3 Calibrate MR 4 Figure 5-7 Carry out single calibration Single calibration is only possible if the "Total calibration" subfunction has been deactivated in function 23. The display will show then number of measuring ranges that were set using function 41. The function screen above is therefore an example of the single calibration of four measuring ranges. If you would like to calibrate measuring range 3, for example, press the corresponding softkey. The setpoint and current actual value of the selected measuring range then appear in the display: 21 Sp. cal. MR 3 MC Setpoint : Act. value: 8O.OO % v/v % v/v Start calibration CANCEL Figure 5-8 Calibrating the measuring range (single calibration) 52 Operating Instructions, 12/2011, A5E

55 Operation 5.3 Calibration When the actual value has stabilized, you can initiate the calibration process by pressing the fourth softkey. The actual value is now made to agree with the setpoint. If you make a mistake during the calibration (e.g. wrong calibration gas), reload the original calibration by pressing the "Cancel calibration" softkey. Total calibration ("Measure" operating mode required) Total calibration is only possible if the "Total calibration" subfunction has been activated using function 23. With a total calibration, you calibrate all measuring ranges together. Define the "leading" measuring range in function 22. We recommend that you use the largest measuring range for this. After selecting this function, the display shows the setpoint and the current value of the "leading" measuring range. 21 Sp. cal. all MRs MC Setpoint : 10O.OO % v/v Act. value: % v/v Start calibration CANCEL Figure 5-9 Calibrating the measuring range (total calibration) When the actual value has stabilized, you can initiate the calibration process by pressing the fourth softkey. The actual value is now made to agree with the setpoint. If you make a mistake during the calibration (e.g. wrong calibration gas), reload the original calibration by pressing the "CANCEL" softkey. Note Measuring accuracy With a switching ratio of the spans of more than 1:10, an individual calibration should be carried out for each range to achieve a higher measuring accuracy. Operating Instructions, 12/2011, A5E

56 Operation 5.3 Calibration Zero/span setpoints (function 22) 22 Setpoints total MC Setpoint for zero : O.OO: % v/v Setpoint for MR 1 50.OO % v/v Setpoint for MR 2 60.OO % v/v Setpoint for MR 3 80.OO % v/v Setpoint for MR 4 1OO.OO % v/v Figure 5-10 Setting the setpoints The function display shows the setpoint input with total calibration. The third measuring range is chosen here as the leading measuring range. With single calibration, there is no choice for the leading measuring range Calibration setting (function 23) 23 Total/single cal. MC Total range calibration Figure 5-11 Select calibration method With this function, select between total and single calibration of the measuring ranges. Total calibration means that you adjust one "leading measuring range" and all other measuring ranges are calibrated using the switching ratio. If the total calibration is not activated, as shown here on the function display, you must calibrate every measuring range individually. 54 Operating Instructions, 12/2011, A5E

57 Operation 5.3 Calibration AUTOCAL (function 24) Note You can only make use of automatic calibration (AUTOCAL) if your device contains additional electronics (add-on board). If it does not, a corresponding message will appear on the display when the AUTOCAL function is called. Automatic calibration can only be started if the device is in the "Measure" operating mode! 24 Autocal/-check MC Autocal/-check mode Autocal/-check sequence Autocal/-check cyclic parameters Autocal check Figure 5-12 AUTOCAL function Note The settings for "Acal/Check..." (subfunctions 1 to 3) are valid both for AUTOCAL (automatic calibration) and for AUTOCAL Check (automatic check that the set calibration tolerances are complied with, without calibration). The settings for "AUTOCAL Check" (4th subfunction) only refer to the check of the calibration tolerances without calibration. Operating Instructions, 12/2011, A5E

58 Operation 5.3 Calibration AUTOCAL/Check operating mode With this AUTOCAL function, you configure various AUTOCAL operating modes. The AUTOCAL Check is only for checking the calibrations. As with AUTOCAL, the device executes the sequence configured in subfunction "AUTOCAL/Check sequence". In contrast to AUTOCAL, no new calibrations are performed; only the deviations are checked with respect to selectable calibration tolerances. Autocal/-check mode MC Autocal/-check on/off Start autocal/-check cyclically Start autocal/-check via binary input Trigger autocal once Abort autocal Figure 5-13 AUTOCAL/Check operating modes "AUTOCAL/Check on/off": During the state "AUTOCAL off" (shown as: " "), the settings on the switch "AUTOCAL start cyclically (parameter)" and "AUTOCAL start via digital input" do not have an effect on the device. "Trigger AUTOCAL once" cannot be selected. A previously set cycle time continues to run, but without triggering automatic calibration. "AUTOCAL/Check start cyclically": You can activate AUTOCAL to be a regularly repeated cycle if you first set a value for "Time from AUTOCAL to AUTOCAL (cycle time)" using subfunction "AUTOCAL/Check cycle parameter". "AUTOCAL/Check start via digital input": If you previously configured a digital input using function 72, you can initiate AUTOCAL via a digital input. The "AUTOCAL start via cycle parameter" and "AUTOCAL start via digital input" operating modes can be activated simultaneously in order e.g. to verify a weekly calibration and control this check via a digital input. 56 Operating Instructions, 12/2011, A5E

59 Operation 5.3 Calibration "Trigger AUTOCAL once" In the "AUTOCAL on" state, you can start an AUTOCAL sequence at any time using the softkey "Trigger AUTOCAL once" providing the device is in the "Measure" operating mode. A sequence initiated this way has no influence on the time cycle of an AUTOCAL, i.e. the cycle time continues to run independent of this. After the initial trigger, the dot disappears until the process is finished. "Abort AUTOCAL" A running automatic calibration process can be exited at any time using the softkey "Abort AUTOCAL". With this, all calibration data determined up to that point are discarded and the calibration data used before AUTOCAL was started are used further (zero and span). Canceling has no influence on the time cycle. All valid calibration processes are retained. AUTOCAL sequence The AUTOCAL sequence is configured in this submenu. Autocal/-check sequence MC 1. Zero gas 1 : 1.O:min 2. Zero gas 2 1.1:min 3. Cal. gas 1 1.2:min 4. Cal. gas 2 1.3:min continue Figure 5-14 AUTOCAL/Check sequence A AUTOCAL can be composed of up to 12 individual steps. Besides the supply of one zero gas and up to four calibration gases per component, you can also program purging with sample gas, sample gas intermediate operation, as well as a signaling contact. The signaling contact is only available if you have previously assigned it to a relay output using function 71. Sample gas intermediate operation Sample gas intermediate operation can be necessary if the system may only leave measuring mode for a certain time. If the sum of the required purge times are greater than the permissible downtime, you must return to the measuring mode between the individual calibrations. Operating Instructions, 12/2011, A5E

60 Operation 5.3 Calibration Signaling contact Use the signaling contact to initiate an automatic calibration process of a second device, for example, or to signal the beginning or end of an AUTOCAL. Relay outputs If you have defined relay outputs for the sample gas, zero gas, calibration gases and/or measuring/calibration (function 71), these are used to activate the corresponding external solenoid valves. The same applies to the signaling contact "AUTOCAL". This is closed for 1 s when the command is executed. Example: You want to program the following sequence: 1. Zero gas calibration: 15 minutes 2. Calibration with calibration gas 1: 10 minutes 3. Purging with sample gas: 8 minutes 4. Sample gas intermediate operation: 30 minutes 5. Calibration with calibration gas 2: 5 minutes 6. Calibration with calibration gas 3: 8 minutes 7. Calibration with calibration gas 4: 11 minutes 8. Purging with sample gas: 8 minutes 9. Short-term signaling contact in order to be able to start AUTOCAL on another device. The specified AUTOCAL sequence is shown in the following function displays. Autocal/-check sequence MC 1. Zero gas 1 :15.O: min 2. Cal. gas 1 1O.O min 3. SG purging 8.O min 4. Int.SG mode 3O.O min continue Figure 5-15 Example of AUTOCAL sequence 58 Operating Instructions, 12/2011, A5E

61 Operation 5.3 Calibration Autocal/-check sequence MC 5. Cal. gas 2 : 5.0: min. 6. Cal. gas 3 : 8.0: min. 7. Cal. gas 4 :11.0: min. 8. Int.SG mode: 8.0: min. continue Figure 5-16 Example of AUTOCAL sequence Autocal/-check sequence MC 9. Sig. cont :I: min. 10. **** min. 11. **** min. 12. **** min. continue Figure 5-17 Example of AUTOCAL sequence List for the AUTOCAL sequence: Step AUTOCAL sequence Zero gas 1 Function code 1 Zero gas 2 Function code 2 Calibration gas 1 Function code 3 Calibration gas 2 Function code 4 Calibration gas 3 Function code 5 Calibration gas 4 Function code 6 Flush sample gas Function code 7 Sample gas intermediate operation Function code 8 Signaling contact Function code 9 Operating Instructions, 12/2011, A5E

62 Operation 5.3 Calibration AUTOCAL/Check cycle parameters With this subfunction, you can configure various time constants for activating a cyclically repeated AUTOCAL sequence. Autocal/-check cycle MC Time from autocal to autocal (cycle time): O: [h] Time up to next autocal 15 [min] Carry out span calibration at any 1st cycle Total range calibration Cal. gas 3 Figure 5-18 AUTOCAL/Check cycle parameters "Time from AUTOCAL to AUTOCAL (cycle time)": Any setting between 0 and (hours) is accepted by the device. "0" corresponds to no AUTOCAL cycle. "Time to first AUTOCAL" (after the time of setting): If you enter "0" here and AUTOCAL is activated with "AUTOCAL on/off" subfunction, the device begins immediately with the AUTOCAL sequence. If AUTOCAL is switched off, the device only starts an AUTOCAL sequence if AUTOCAL is switched on within one minute after entering "0". If not, the total time between two AUTOCAL cycles passes by, starting with the input of "0". Note The clock inside the device also runs when AUTOCAL is deactivated! It starts the first time the device is switched on with the factory-set start time and must be set to the current time using function 58. "Carry out span calibration for each xth cycle": Here you set the number of cycles after which a calibration with the calibration gas is to be carried out. If you would like to save on calibration gas, for example, and not calibrate the span along with every zero calibration, enter in the line "Calibrate with calibration gas at every : : cycle" an integer > Operating Instructions, 12/2011, A5E

63 Operation 5.3 Calibration Information in the last two lines The information in the last (bottom) lines indicates that specified parameters relate to total calibration with calibration gas for measuring range 3. This measuring range was selected beforehand with function 22. Note As long as AUTOCAL is activated (AUTOCAL ), access to functions 20 and 21 is blocked. If you activate these functions anyway, a corresponding message appears on the display. Settings for AUTOCAL Check The "AUTOCAL Check" subfunction is only used for checking the calibrations. Similar to "AUTOCAL", sequence set in the "AUTOCAL Sequence" menu is performed. In contrast to "AUTOCAL", no new calibrations are performed; only the deviations are checked with respect to selectable calibration tolerances. Autocal check MC Calib. tolerance at zero in % of smallest MR : 6: Calib. tolerance at sens. in % of current MR : 6: Start only Autocal check cyclically Trigger acal check once Abort autocal check Figure 5-19 AUTOCAL Check Functions of the AUTOCAL Check In the "AUTOCAL Check" subfunction, enter the desired calibration tolerances to be checked by AUTOCAL Check. Using functions 71 and 72, you can also select the relay output or digital input for "AUTOCAL Check". When a calibration limit is exceeded, the maintenance request W10 is set, and also, if configured, the relay "Acal Chk Dif". Both will be reset again after an error-free AUTOCAL Check. W10 is retained in the logbook. "When starting via cycle, initiate AUTOCAL Check": If this function is activated, the device executes an AUTOCAL Check when AUTOCAL is started via a cycle. In other words, it only checks that the calibration tolerances are observed, but does not carry out a calibration. Operating Instructions, 12/2011, A5E

64 Operation 5.3 Calibration Sequence: 1. Start the AUTOCAL Check: By means of the softkey "Trigger AUTOCAL Check once" in the subfunction "Acal/Check sequence" Via digital input Via cycle 2. The device executes the sequence as configured in the subfunction "Autocal/Check sequence" Drift values (function 25) This function shows deviations occurring for the calibrations (and AUTOCAL as well ) (actual value - setpoint) as a sum parameter. All rated zero point and sensitivity calibrations of each range are calculated here for the selected measured component. Every new deviation is added to the existing drift value. 25 Drift values MC Zero : 0.00 vpm Span MR4: vpm Drift values reset Figure 5-20 Drift values The display of the drift values for the sensitivity calibration depends on the setting of the calibration method. If total calibration is selected here, only the selected measuring range for the sensitivity calibration is displayed. For single calibration, all measuring ranges can be individually adjusted and can therefore have different drift values, which are shown separately. The drift values can reset to 0.0 with the 'Reset drift values' instruction. When you reboot the device all measuring ranges have 0.0 as the drift value. 62 Operating Instructions, 12/2011, A5E

65 Operation 5.4 Measuring ranges 5.4 Measuring ranges After selecting the measuring range functions in the main menu, the following screen appears when the third softkey ("Measuring ranges") is pressed. Meas. ranges MC 4O Range selection 41 Define meas. ranges Figure 5-21 Measuring ranges submenu The measuring ranges menu contains all functions you need for selecting and setting the measuring ranges. This menu is protected by the code of code level Select measuring ranges (function 40) 4O Select range MC MR1 MR2 MR3 MR4 O.O - 50.O % Vol O.O - 60.O % Vol O.O - 8O.O % Vol O.O - 1OO.O % Vol Autorange Figure 5-22 Select measuring ranges You can select a fixed measuring range or switch to automatic measuring range switching. All selection options are subject to mutual interlocking. Automatic measuring range switching is only possible under the following conditions: At least two measuring ranges must be available. A measuring range is said to be present when the following is true: Start-of-scale value full-scale value The measuring spans must become greater or smaller The measuring ranges must "border on" each other or overlap Operating Instructions, 12/2011, A5E

66 Operation 5.4 Measuring ranges Measuring range types The permissible measuring range constellations result which are shown in the figure below: Figure 5-23 Measuring range types Two measuring range types are distinguished: Type A: The full-scale value must be smaller than the full-scale value which follows it. The top measuring range limit therefore becomes larger with every measuring range. SSV FSV LS HS Start-of-scale value Full-of-scale value Low switchover point: select smaller measuring range High switchover point: select larger measuring range Figure 5-24 Measuring range type A 64 Operating Instructions, 12/2011, A5E

67 Operation 5.4 Measuring ranges The following applies to measuring range switching: Figure 5-25 Measuring range switching, type A When the upper switchover point (OU) is exceeded, the next larger measuring range available is selected. If the lower switchover point (UU) of the next smaller measuring range available is fallen below, this is selected. The UU lies at 80 % (HystS) of the measuring range. The OU lies at 90 % (HystE) of the measuring range. Type B: The full-scale value must be greater than or equal to the full-scale value following it. Since the measuring spans must simultaneously become larger, the start-of-scale values of the following measuring ranges become continuously smaller. SSV FSV LS HS Start-of-scale value Full-of-scale value Low switchover point: select smaller measuring range High switchover point: select larger measuring range Figure 5-26 Measuring range type B The following applies to measuring range switching: Figure 5-27 Measuring range switching, type B Operating Instructions, 12/2011, A5E

68 Operation 5.4 Measuring ranges When the upper switchover point (OU) is fallen below, the next larger measuring range available is selected. If the lower switchover point (UU) of the next smaller measuring range available is exceeded, this is selected. The UU lies at 10 % (100 % - HystE) of the measuring range. The OU lies at the start of the measuring range (mba) Define measuring ranges (function 41) 41 Define range MC MR Start End value No. 1: O.OO: 50.OO % v/v 2 O.OO 60.OO % v/v 3 O.OO 80.OO % v/v 4 O.OO 1OO.OO % v/v Figure 5-28 Define measuring ranges You can define a maximum of four measuring ranges whose start-of-scale values are allocated to the bottom value (0/ 2/ 4 ma) and whose full-scale values are allocated to the top value (20 ma) of the analog output. If the message "Measuring ranges not plausible!" appears, this means that autoranging is not possible. If the start-of-scale and full-scale values are "0", the measuring range is deactivated. Note If a start-of-scale value other than "0" is defined, you must read the section "Preparations for start-up - temperature influence". 66 Operating Instructions, 12/2011, A5E

69 Operation 5.5 Parameters 5.5 Parameters Parameters MC 5O El. time constants 51 Limits 52 On/off configuration 53 Status messages continue Figure 5-29 Parameters submenu The parameters menu contains all functions which are required for configuring the device. After selecting the parameter functions in the main menu by pressing the fourth softkey ("Parameters"), the menu screen for the selection of parameter functions 50 to 53 appears. Pressing the fifth softkey "...Continue" brings you to additional parameter functions. This menu is protected by the code of code level 1. Operating Instructions, 12/2011, A5E

70 Operation 5.5 Parameters Electric time constants (function 50) 5O Electr. time con MC Effective bandwidth in % of smallest MR : : 6.O:% Time constant within bandwidth ti : :1O.O:s Time constant outside bandwidth ta : : 1.O:s Actual measured value: O.OO % v/v Figure 5-30 Electric time constants With this function, you set various time constants, which reduce the underlying noise in an message value signal. The noise reduction is approximately equivalent to a low-pass filter with the corresponding time constant. The display delay is given as the 90 % time. The time constant "ti" acts within an configurable effective interval which is defined in % of the smallest span. It attenuates small changes in the measurement (e.g. noise) on the one hand, but becomes ineffective immediately when the measured value exceeds the effective interval. In this case, the outer time constant "ta" attenuates the measured value. You can configure values up to 100 % for the effective interval, and values up to 100 s for the time constants "ti" and "ta". By cleverly combining these three parameters, you can achieve a low display delay (90 % time) despite high noise suppression. The effect on the configured attenuation parameters can be observed in the bottom line. The "live" measured value is displayed here. 68 Operating Instructions, 12/2011, A5E

71 Operation 5.5 Parameters Limits (function 51) 51 Limits MC Limit 1 : O.OO:% v/v on relay - Alarms at decrease signal Applies to MR Limit alarm on/off Limit 2 Figure 5-31 Limits The device monitors up to four limits, and these limits can be allocated to any measuring range. Each limit can be allocated to any relay using function 71. If this was not configured, the "--" indicator appears in the limit screen. You can only configure positive limits up to 100%. "Alarms at decrease signal": Here you select whether a limit alarm is to be switched if the entered limit is exceeded or fallen short of. "Applies to measuring range...": Here, you allocate the limit to the desired measuring range(s) by pressing the third softkey several times. When you do so, the pointers move over the measuring range numbers and indicate the ranges in which the limit monitor is to be active. The menu screen shown here is for measuring range 3. "Limit alarm": The limit monitoring of every single limit can be switched off individually using function 52. Resetting the limit alarm If the limit relay is triggered, this state is obtained even when the measured value goes back to the permissible range. The response of a limit relay is registered in the logbook (function 3). As soon as the cause of the limit alarm has been eliminated, the limit relay is reset automatically. You can change to the next limit using the fifth softkey ("Limit "). Operating Instructions, 12/2011, A5E

72 Operation 5.5 Parameters On/off functions (function 52) On/off config. MC Auto range Stored function continue Figure 5-32 On/off functions With this function, you can easily switch other functions on/off, for example, the ones listed in this function screen. Thanks to this simplified operation, these functions do not have the longer paths through various menus and submenus. For better orientation, the function numbers have also been specified. Activated functions are marked by " ", deactivated ones by " ". Using the fifth softkey ("...continue"), jump to the next function screen with further functions. Function 52 is used to switch the following functions on and off: Table 5-3 Functions switched on/off by function 52 Description Fct. no. Remarks Total calibration 23 AUTOCAL 24 Only with supplementary electronics Automatic measuring range switching 40 Limit monitoring 1 51 Limit monitoring 2 51 Limit monitoring 3 51 Limit monitoring 4 51 Suppression the display of negative measured values 55 Blocking of the logbook 60 Suppression the display of negative measured values 70 Fault / WA / FCTRL acc. to NAMUR 72 Measured-value memory 77 Signal tolerance violation 78 Temperature recompensation of zero point 86 Temperature recompensation of span Operating Instructions, 12/2011, A5E

73 Operation 5.5 Parameters Besides the functions listed in the table "Functions switched on/off by function 52", function 52 can also be used to address other service functions. These are restricted to service engineers and are only visible when the service code is entered (code level 3) Status messages (function 53) 53 Status messages MC Display automat. calibration [CAL] Display stored value [STO] Display limit [LIM] Display autorange [AR] Display control function [CTRL] Figure 5-33 Status messages With this function, you can configure the status message display in the status line of the measured value display. You can display a maximum of four different status messages. The message CODE / provides information on the current operating mode ("Coded display mode"/"decoded display mode") and is therefore always displayed. The device activates the functional check (softkey 5 in the function display) when it determines that the measured value was influenced. This is the case: During the warm-up phase After entry of a code (i.e. switch to "Operator control mode") During automatic calibration (AUTOCAL) or remote calibration Operating Instructions, 12/2011, A5E

74 Operation 5.5 Parameters Table 5-4 Status Status messages What appears in the display depends on functions 52 and 53 Fct. 53 " " Fct. 52 " " Fct. 53 " " Fct. 52 " " Fct. 53 " " Calibration: CAL None CAL CAL CAL; calibration running (also in Autocal) Measured value memory: STO None STO STO STO; analog output applied to memory (see function 77) Limit: LIM None LIM LIM LIM; limit has been violated (see function 51) Automatic measuring range switching: AR Functional check: CTRL None AR AR AR; measuring range switching (actively possible), see function 40 None CTRL or CTRL (functional check cannot be switched off using function 52) CTRL CTRL; device is in the "Warmup phase" or in "Operator control mode" or calibration is in progress If an error occurs during operation, the message "Maintenance request", "Fault" or "Measuring protection" appears in the status line, depending on the severity of the error. This message is alternately displayed with the status messages. In addition, when communication is over the ELAN interface, the message "Remote" is displayed also alternating with display of the device status Graphical representation of measured values (function 54) With this function, you can follow the trend of the measured values for the last ten minutes or 24 hours on the display. 54 G. signal display MC Period 1O min Period 24 h Figure 5-34 Graphical measured value representation 72 Operating Instructions, 12/2011, A5E

75 Operation 5.5 Parameters Select the desired time period with softkey 1 or 2. The device now graphs the measured value vs. time: Val. display 1O min MC 1.1 O.9 O.7 O.5 O.3 O.1 % v/v Parameter min O O Figure 5-35 Measured value trend The most recent measured value is on the time axis at the left at t = 0. Select softkey 1 "Parameters". Here, assign a certain measuring range to the measured value axis: Meas. value disp. par. MC Optimum meas. val. dis. Range 1 Range 2 Range 3 Range 4 Figure 5-36 Parameters for measured value representation If you select "Optimum measured-value display", the software automatically scales the measured value axis. The device adapts the scale to the measured value scatter. Operating Instructions, 12/2011, A5E

76 Operation 5.5 Parameters Measured value display (function 55) With this function, you can configure the display of measured values. 55 Select digits MC Suppress negative measured values Automatic Total digits 5 Digits after 3 decimal point The decimal point counts as a digit Figure 5-37 Configuring the measured value display You have the following options for this: With softkey 1, you suppress the display of negative measured values. With softkey 2 "Automatic", you can activate the automatic display of the measured value with 5 digits. The number of decimal places depends on the size of the measured value. With the softkeys 3 and 4, you can choose the total number of digits and the maximum number of decimal places. Note that a maximum of five digits can be displayed (decimal point also counts as one digit) LCD contrast (function 56) With this function, you can make the display contrast brighter or darker. 56 LCD contrast MC brighter darker Basic setting Test Figure 5-38 Setting the LCD contrast 74 Operating Instructions, 12/2011, A5E

77 Operation 5.5 Parameters If the contrast is misadjusted, you can restore the factory settings using the third softkey "Basic settings". With the fourth softkey "Test", you can carry out an LCD test. Various test screens are then displayed in succession. From "Coded/decoded display mode", you can restore the basic setting by entering [8] [8] [8] [8] [ENTER] Magnetic field frequency (function 57) You can use this function, for example, to minimize vibration-dependent frequencies superimposed on the analog output (beat) or even eliminate them in the ideal case. 57 Magn. field freq. O2 Frequency: Default value :8.086:Hz Hz Figure 5-39 Magnetic field frequency To do this, enter the desired frequency value in the "Frequency" input field by calling function 57. The permitted values for this are between 7 to 11 Hz. If the change to a specific frequency does not have the desired effect, enter different frequency values. Pressing the fifth softkey resets clock frequency back to the factory default of Hz. NOTICE Calibration of zero point and sensitivity After each frequency change, the zero point and sensitivity must be calibrated again. Operating Instructions, 12/2011, A5E

78 Operation 5.5 Parameters Date/time (function 58) With this function, you can set the date and time. 58 Date/Time MC New date (dd.mm.yy;24h/day :O1:. O3. O7 New time: 12 : 53 Set clock Actual date Actual time: O1.O3.2OO7 12:53 Figure 5-40 Setting the date/time The device features a system clock that is not buffered against mains failure (no a real-time clock). When starting the device, the clock starts with the date When the function is called, the cursor is placed at the first place of the date display. Enter the new settings in the order: day, month, year. By pressing [ENTER], jump to the next input field. With a 24-hour based system (hours, minutes), set the time in the same way. NOTICE When the device is switched off, the clock stops and is not updated. The settings are especially important for troubleshooting. Errors which are always stored in the logbook (function 60) can be allocated more easily with the help of the date and time. Press the third softkey "Set clock" in order to accept the set data. These then appear at the bottom edge of the display. 76 Operating Instructions, 12/2011, A5E

79 Operation 5.5 Parameters Measuring point switching (function 59) With this function, you can assign the device up to six measuring points, which are switched automatically at the expiration of a configured period. 59 Sample selection MC M. pt. 1 Rel. 2 : 45: min M. pt. 2 Rel. 1 2O min min min min min M. p. switching on/off Figure 5-41 Measuring point switching The condition is that you configured the measuring point relay beforehand using function 71 "Relay outputs", which then actuates the corresponding solenoid valves. Every measuring point relay is also allocated a time period, which you can enter in the respective input field. Values between 0 and 60 (minutes) are possible for this input. Press the fifth softkey to activate/deactivate the measuring point switching. You can allocate a signal relay to each measuring point relay. This allows measuring point identification separate from the measuring point relay. You also use function 71 to configure the signal relay Logbook settings (function 60) With this function, you delete or block logbook entries. 6O Setup logbook MC Clear logbook Lock logbook Figure 5-42 Configuring the logbook Status messages such as maintenance requests or faults cannot be suppressed by "blocking". They still appear, despite the blocked logbook. Operating Instructions, 12/2011, A5E

80 Operation 5.6 Configuration 5.6 Configuration This menu contains all functions required for configuring the device. Configuration MC 7O Analog output 71 Relay outputs 72 Binary inputs 73 ELAN configuration continue Figure 5-43 Configuration submenu All functions of this menu are only accessible via the code of level 2. Press the fifth softkey ("...continue") to branch to further configuration functions Analog output (function 70) With this function, you can configure the analog output. 7O Analog output MC 4-2O ma Output inverted Suppress negative measured values Figure 5-44 Configuring the analog output With softkey 1, define the start-of-scale value of the measuring range. The following settings (see also table "Configurations of the analog output") are possible: 0 20 ma 2 20 ma 4 20 ma NAMUR/4 20 ma (with limit at 3.8 ma). 78 Operating Instructions, 12/2011, A5E

81 Operation 5.6 Configuration You can invert the analog output with softkey 2: e.g % O ma % O ma With softkey 3, you can suppress the negative measured values. If a negative value has an unfavorable effect on further processing, the negative measured values at the analog output can be limited to 0 (or 2/4/3.8 (NAMUR) ma) when this function is activated. The display continues to show the actual measured value. Table 5-5 Configurations of the analog output Defined analog output / ma Measuring range limit in normal operation Measuring range limit in case of fault / CTRL Start-of-scale value / ma Full-scale value / ma Start-of-scale value / ma (NAMUR) 3, Full-scale value / ma Note If the electronics is defective, it is possible that the analog output may get stuck at approx. -1 ma or approx. +24 ma. Operating Instructions, 12/2011, A5E

82 Operation 5.6 Configuration Relay outputs (function 71) With this function, you can assign each relay functions listed in the table "Relay outputs (possible functions)", whereby you may only assign each function once. In other words, for example, "Fault" may not be assigned to two relays at the same time. 71 Relay outputs MC R 1 Fault R 2 Maint. req. R 3 Funct. cont. R 4 not used continue Figure 5-45 Assigning the relays There are six freely configurable relays included in the standard equipment whose switchable output contacts (max. 24 V/1 A) can be used for signaling, actuating valves, etc. If these six relays are insufficient, you can retrofit additional electronics with eight further relays (add-on board). The connection assignments for the individual relays in the zero-current state can be found in the routing assignments "Motherboard pin assignments". The relays are preset at delivery. Press the fifth softkey ("...continue"), to access the next function screen, thus branching to further relays. NOTICE Changing the configuration Every change to the configuration of the relay assignments should always be saved in the user data memory by means of function 75. If you neglect to do this, there is a danger that a previous (unwanted) configuration will be loaded by "Load user data" (function 75). 80 Operating Instructions, 12/2011, A5E

83 Operation 5.6 Configuration Table 5-6 Relay outputs (possible functions) Function Relay is passive when Relay conducts current Remark Not assigned Relay is permanently passive (zero current) Fault Fault Also shown in the status line of the measured value display Maintenance request Maintenance request Calibration Calibration running For identification purposes Measuring range 1 to 4 Measuring range 1 to 4 on Measuring range identification Limit 1 to 4 Limit 1 (to 4) triggered Limit monitoring Functional check Signal when: (CTRL) Sample gas Zero gas 1 Calibration gas 1 to 4 Measuring point 1 to 6 Measuring point signal 1 to 6 Signaling contact Sample gas flow Reference gas pressure AUTOCAL Check Functional check active (e.g.: when changing to "Operator control mode", in the warm-up phase, when Autocal is running, when calibration is running) Autocal difference too large (function 24) Decoding, warm-up phase, Autocal running Supply of sample gas Supply of zero gas Supply of calibration gas Measuring point 1 to 6 selected Measuring point 1 to 6 selected When there's a signal, the relay conducts current for a short time Sample gas flow too low Reference gas pressure too low Device is decoded, Warm-up phase (approx. 30 min), Calibration running (Autocal) Remote Valve actuation for Autocal For taking a gas sample via solenoid valves at various measuring points For identifying the measuring point (runs parallel to measuring point) e.g. in the case of AUTOCAL: actuation of a second device For identification purposes For identification purposes Operating Instructions, 12/2011, A5E

84 Operation 5.6 Configuration Binary inputs (function 72) Digital input functions Six floating digital inputs are included in the standard equipment ("0" = 0 V [0 to 4.5 V]; "1" = 24 V [13 to 33 V]). If these six inputs are insufficient, you can retrofit additional electronics with eight further digital inputs (add-on board). 72 Binary inputs MC Fault/Maint.r/CTRL NAMUR Binary inputs define Figure 5-46 Digital input function The operation of the digital inputs are defined with softkey 1. If you activate the "NAMUR" (" ") operating mode, the digital inputs behave as in table "Digital input activation functions" marked with "N". If you deactivate the "NAMUR" (" ") operating mode, the digital inputs behave compatibly with the software outputs of the older version V (in the table "Digital input activation functions" marked with "X"). Press softkey 2. The following function screen appears on the display. 72 Binary inputs MC D 1 Autocal Check D 2 Vacant D 3 Vacant D 4 Vacant continue Figure 5-47 Define digital inputs 82 Operating Instructions, 12/2011, A5E

85 Operation 5.6 Configuration Assign one of the activation functions listed below to each input as you like, whereby every function may only be assigned once. The connection assignments for the individual inputs can be found in the section "Electrical connection". No digital input has been preassigned in the factory. Up to four digital inputs can be configured in a menu screen. Press the fifth softkey ("...continue"), to access the next function screen, thus branching to further digital inputs. NOTICE Save changes Make sure you save every change in the configuration of the digital inputs in the user data memory using function 75! If you neglect to do this, there is a danger that a previous (unwanted) configuration will be loaded by "Load user data" (function 75). Table 5-7 Function Digital input activation functions Necessary activation voltage Remark / effect 0 V 24 V 24 V pulse (min. 1 s) Not assigned No effect when activated External fault 1 to 7 External maintenance request 1 to 7 N N X X e.g. due to: Signal from a gas preparation system: Condensate overflow Gas cooler fault see also section 'Maintenance requests and fault messages" Deleting the logbook entries Function check (CTRL) 1 to 4 N, X After deletion, the device is restored to the initial state. If the cause of a fault or maintenance request is not eliminated, the corresponding message reappears in the logbook. N X Relay must be configured for functional check using function 71 if, for example, the function is to be checked by a second device. Start AUTOCAL N, X Note: Effective activation only possible in "Measure" operating mode! AUTOCAL must be configured (functions 23, 24 and 25). Measuring range 1 to 4 on N, X For measuring range switching Note: Automatic measuring range switching (function 52) must be turned off Operating Instructions, 12/2011, A5E

86 Operation 5.6 Configuration Function Necessary activation voltage Remark / effect Zero gas on Calibration gas on Sample gas on 0 V 24 V 24 V pulse (min. 1 s) N, X Note: Effective activation only possible in "Measure" operating mode! Relay function under 71 must be set to zero gas (calibration gas, sample gas) and the corresponding valves to be connected. Applies only to total calibration, since only one calibration gas can be used (function 22) Zero calibration Span calibration N, X Activation initiates calibration. See also "Example - digital inputs" Autorange N, X Activate "Automatic measuring range switching" Autocal check N, X Note: Effective activation only possible in "Measure" operating mode! Start Autocal check (function 24) Measuring protection N, X It is possible to define a digital input "Measuring protection" which has the following effect: If the device is in the "Measure" operating mode (functional check deactivated), it remains in this state, i.e.: The device can no longer be decoded. The device can no longer be set to "Remote". The message "Measuring protection activated" appears in the status line of the measured value display. 84 Operating Instructions, 12/2011, A5E

87 Operation 5.6 Configuration ELAN configuration (function 73) With this function, you set the parameters for an ELAN network. 73 ELAN config. O2 Channel address Measured value telegram: ELAN tag O1 : OXY61 Figure 5-48 Configuring ELAN Channel address: Set the channel address for the device here. Addresses from 1 to 12 can be set. In an ELAN network, each address may only be used once. Addresses of devices that are used to correct the pressure or the influence of interfering gas may not be entered at this location. Measured value telegrams on/off: Here you can switch the cyclic, independent transmission of measured values on or off every 500 ms. Note Independent sending of measured values If you have set up your own communication control system, this option offers a simple way of checking an ELAN telegram. In order to avoid unnecessarily loading the device and the ELAN network, however, the function should only be switched on as needed! ELAN tag: Display of the tag assigned to the device in the ELAN network. For more details, refer to the ELAN interface description (Order no.. C79000-B5200-C176 German, C79000-B5276-C176 English). Operating Instructions, 12/2011, A5E

88 Operation 5.6 Configuration Reset (function 74) With this function, you can carry out a warm restart. 74 Reset MC Trigger reset Figure 5-49 Carrying out a reset After calling this function, the device switches to the "Warm-up phase", which activates the functional check at the same time. The device is only completely ready for operation again after successfully running through this phase Save, load data (function 75) You can configure the user data memory with this function: 75 Save data MC Save user data Load user data Load factory settings Figure 5-50 User data memory Press the softkey 1 "Save user data" e.g. after the system has been successfully commissioned. All individual settings are then saved. Press the softkey 2 "Load user data", to load the last user data saved. These functions are important when the device is undergoing repairs or maintenance work, or, for example, if new parameter settings are to be tested. 86 Operating Instructions, 12/2011, A5E

89 Operation 5.6 Configuration Press softkey 3 to restore the factory settings. A confirmation query is set up in this function. In order to actually load the respective data in the memory, you must confirm with "yes". If you select "no", this is cancelled. NOTICE Make sure you save every change in the configuration of the relay outputs in the user data memory using function 75! If you neglect to do this, there is a danger that a previous (unwanted) configuration will be loaded by "Load user data" (function 75). The following figure shows an overview of the interaction between the various memory modules. Figure 5-51 Memory modules Operating Instructions, 12/2011, A5E

90 Operation 5.6 Configuration Suppression of short noise signals (function 76) With function 76, you can eliminate undesired spikes which exceed a settable threshold. 76 Suppress fault. MC Suppress noise signals with a duration of up to : O.O: s Level in % of smallest MR: 12.O % Figure 5-52 Suppressing noise Spikes are created by electromagnetic interferences or sometimes by mechanical shocks. These faults can be suppressed by entering a "blanking time" of 0 to 5 s. The entered time has the effect that the last measured value before the spike occurred is displayed so that the measured result is not influenced. Times can be entered in steps of 0.1 s. Under "Level in % of smallest MR", enter the threshold value in % of the smallest measuring range above which the noise signals are to be suppressed. Note If a change in concentration directly follows a fault, this may be displayed after a delay. When this function is activated, the settings of function 50 ("Electric time constants") must be taken into account, since these are executed first. 88 Operating Instructions, 12/2011, A5E

91 Operation 5.6 Configuration Measured value memory (function 77) This function is used to define the response of the analog output or the digital interface when the device assumes a specific state. 77 Store MC Analog out. to meas.value Analog out. to O/2/4 ma Analog out. to 21 ma Store on/off Figure 5-53 Setting the analog output In case of a fault (S) or CTRL (decoding, calibration, warm-up phase), one of these values is sent to the analog output: The last registered measured value or 0 (2/4) ma or 21 ma 'Memory on' ( ) activates the respective setting Calibration tolerances (function 78) Setting the calibration tolerances With this function, you define the calibration tolerances. 78 Calib. tolerance MC Calib. tolerance at zero in % of smallest MR: :1O: Calib. tolerance of sens. in % of current MR: 1O Signal tolerance violation Figure 5-54 Setting the calibration tolerances Operating Instructions, 12/2011, A5E

92 Operation 5.6 Configuration With softkey 3 "Signal tolerance violation", you activate or deactivate the tolerance monitoring. If you previously configured a relay output to "Maintenance request" using function 71, the device outputs the changes in the zero point or the span with respect to the last calibration as "Maintenance request". Note In order to be able to use this function, "Total calibration" (function 23) must be activated. With "Calibration tolerance at zero point...", you define the max. deviation proportional to the smallest measuring span in %. With "Calibration tolerance at span...", you define the max. deviation proportional to the current measuring span in %. The calibration tolerance, which can be set from 0 to 99 %, refers to the measuring range with the smallest measuring span in the case of the zero point, and to the measuring range where the total adjustment is carried out (marked with " " in function 22) in the case of the span. Example Measuring range 1 95 to 100 % O2 Measuring range 2 90 to 100 % O2 Smallest span ( %) O2 = 5 % O2 Measuring range in which calibration takes place Measuring range 2 Selected calibration tolerance 6 % Response threshold for zero point 5 % O2 x 0.06 = 0.3 % O2 Response threshold for span 10 % O2 x 0.06= 0.6 % O2 If the zero / span deviates by more than the configured value compared to the last calibration, and if "Signal tolerance violation" is activated, the corresponding relay signals a maintenance request. 90 Operating Instructions, 12/2011, A5E

93 Operation 5.6 Configuration Change codes (function 79) With this function, you replace the factory-set codes ("111" for level 1, "222" for level 2) by your own. 79 Codes program. MC Code 1 :111: Code Figure 5-55 Change codes If you enter the value "000" for a code, code blocking is canceled and you have immediate access to the corresponding operation level Device test (function 80) You can check the functionality of the device by performing the following three tests. 8O Analyzer test MC Keyboard Relay-and-Binary test Analog test Figure 5-56 Testing the device Keyboard test You can test all keys on the control panel by means of the keyboard test. The five softkeys on the right edge can be used to make the associated item appear/disappear. If a number key or the sign key is pressed, this is displayed in the bottom line of the display. After pressing the [INFO] key, a message is displayed in plain text. The [MEAS] and [ESC] keys retain their "jump back" function. Operating Instructions, 12/2011, A5E

94 Operation 5.6 Configuration Relay and binary test Relay-and-Binary MC No. Relay Binary 1 :0: O 2 1 O 3 1 O 4 0 O 5 0 O 6 1 O continue Figure 5-57 Test relay outputs and digital inputs The first function screen shows the state of the six relay and digital inputs of the standard device. With an add-on board, there are another eight relay/digital inputs on a second page. With the relay test, individual relays can be activated. This is done via the input field. With "1", the relay is on, with "0", it returns to its release condition. Numbers other than "0" and "1" are not accepted by the input field. After leaving function 80, the relays are back in the state they had before calling the relay and binary test. The current state of the digital inputs is displayed in the "Binary" column. Analog test With the analog test, the analog output is set to a constant current of 0 to µa for testing purposes. The analog input displays the input currents in µa. 92 Operating Instructions, 12/2011, A5E

95 Operation 5.6 Configuration Language selection (function 81) With this function, you set the device to a second dialog language. 81 Select language MC English Deutsch Figure 5-58 Selecting a language The device is always delivered in the ordered language. Usually, English is included as a second language (if English is the first language, Spanish is set as the second language) Pressure correction (function 82) Variations in the sample gas pressure can be corrected within the range from 800 to 1200 hpa (absolute) with the. This function offers the possibility for pressure correction using one of the following options: Pressure correction using an internal pressure sensor Pressure correction using an external pressure sensor via analog input 2 *) (example as shown) Pressure correction using an external pressure sensor via ELAN (RS485). 82 Pressure corr. O 2 With ext. pressure signal on analog input 2 Analog inp. 2: O to 2O ma for range: : O: hpa Figure 5-59 Pressure correction via analog output 2 The pressure correction can also be switched off using function 52 ("On/off functions"). Operating Instructions, 12/2011, A5E

96 Operation 5.6 Configuration Pressure correction using an external pressure sensor via ELAN 82 Pressure corr. O 2 With ext. pressure signal from ELAN Channel :: 4: NO: 994 hpa CTRL Figure 5-60 Pressure correction via ELAN Note Measured value "Pressure" The measured value "Pressure" is an internal value in the gas analyzer which can be supplied to another gas analyzer via ELAN. It is basically possible to use other pressure measuring instruments or analyzers with pressure measuring function and ELAN capability for the pressure measurement. On the device supplying the pressure data, the parameter "Measured value telegrams" must be set to "On" using the function Correction of cross-interference (function 83) Associated gases contained in the sample gas (interfering gases) can affect the measurement. This function is used to reduce such interference or eliminate it altogether in the ideal case. Note A correction for interfering gas is usually only useful if the corrected O2 equivalent is not greater than the smallest span. When the reference gas and residual gas have different compositions (= sample gas without O2 content), a zero point offset (interfering gas swing) occurs triggered by the paramagnetic or diamagnetic difference of the two gases. The value of this zero point offset can be specified to compensate for this offset. Note A differentiation must always be made with the correction of cross-interference as to whether the interfering gas has a constant or variable concentration. 94 Operating Instructions, 12/2011, A5E

97 Operation 5.6 Configuration Press the first softkey. The following function screen appears on the display. 83 Interf. correct. O 2 No interference correct. Figure 5-61 Carrying out correction of cross-interference By pressing the first softkey you now select the type of cross-interference correction. The following distinctions are possible: No correction of cross-interference Correction of cross-interference with constant influence of interfering gas Correction of cross-interference with variable influence of interfering gas via analog input Correction of cross-interference with variable influence of interfering gas via ELAN Note The correction of cross-interference is deactivated for the duration of a calibration process (zero or span). It is active again when calibration has been completed and the device has returned to the "Measure" operating mode. Correction of cross-interference with constant influence of interfering gas 83 Interf. correction O 2 With const. interference correction Valid for range Interference: :-O.43 : Figure 5-62 Constant influence of interfering gas Operating Instructions, 12/2011, A5E

98 Operation 5.6 Configuration With constant residual gas composition and low concentration of O2, a residual gas effect occurs, which varies only by fluctuations in O2 content and can therefore be regarded as approximately constant. The device must be informed of the value of the zero point offset (interfering gas swing) (see Example 1). Example 1: The residual gas (sample gas without O2; zero gas) is 50 % propane, remainder is N2. N2 is used as a reference gas. 1. Determine the influence of interfering gas: The diamagnetic zero point offset (O2 equivalent) of the propane is % O2. With content of 50 %, the interfering gas swing would be % O2. 2. Enter the interfering gas swing (her % O2). Correction of cross-interference with variable influence of interfering gas 83 Interference corr. O 2 With var. interference influence on an. input 1 Valid for range Interfering gas: 100 %: causes an interference: :42.94: Analog in 1 : 4-2O ma for range : O.OO - 5.OO Figure 5-63 Variable influence of interfering gas Example of a variable cross-interference correction: The concentration of the interfering component must be measured with a suitable analyzer and the corresponding analog signal must be transmitted to the for inclusion in calculations. A pure residual gas should be specified as the interfering gas swing (O2 equivalent). By specifying the measuring range of the residual gas analyzer as a % as well as its electricity output, an internal calculation of the actual O2 offset can be made. Example 2: A sample gas is composed of 4% NO and 96% N2. It should be monitored for O2. The O2 equivalent of 100% NO amounts to 42.94% O2. The NO analyzer has a measuring range of 5 % NO and an analog output from 4 to 20 ma. 96 Operating Instructions, 12/2011, A5E

99 Operation 5.6 Configuration Correction of cross-interference via ELAN 83 Interf. correction O 2 With var. interference influence on ELAN Valid for range Interfering gas : 100 %: causes an interference : Channel: :03: Comp.: :1: NO : 5 % CTRL Figure 5-64 Correction of cross-interference with variable influence via ELAN If the cross-interference correction is performed via the serial RS485 interface (ELAN), the same specification must be made as for the cross-interference correction with a variable interfering gas influence. Also enter the channel number and component number of the interfering gas analyzer. The type of gas allocated to the channel and component, the measuring range and possibly the device status appear in the display (see also function 82 "Pressure compensation"). With softkey 2, you can set whether this correction of cross-interference should only apply to certain measuring ranges. Note On the device supplying the correction data, the parameter "Measured value telegrams" (function 73) must be set to "On". Operating Instructions, 12/2011, A5E

100 Operation 5.6 Configuration Phase adjustment (function 84) The physical principle of the measurement procedure and the mechanical design of the detector result in a delayed reaction (phase offset) of the analog measured value signal compared to the clock signal of the magnet controller. This phase shift can be adjusted if necessary with the help of this function. 84 Phase adjust O 2 V W : 31,2 : Meas.value 20,95 % Phase adjust Figure 5-65 Phase adjustment With the maximum possible signal (sample gas: e.g. air) the gain is automatically adjusted so that V assumes a value of approximately 500,000. The phase angle φ is then calculated using this signal value and saved, whereby V is maximized and W minimized. This angle was determined at the factory and should only be readjusted when the magnetic field frequency is changed. 98 Operating Instructions, 12/2011, A5E

101 Operation 5.6 Configuration Switch valves (function 85) With this function, you can manually switch up to six valves. This is done via the relays which are allocated to the individual valves and are available on the motherboard and add-on board. The precondition is that the corresponding relays have been previously configured with function 71 ("Relay outputs") 85 Switch valves O 2 01 Zero gas Rel. 3 Figure 5-66 Switching valves The "Switch valves" function only applies to the relay functions "Zero gas", "Calibration gas 1 to 4" and "Sample gas". Only one of the six valves can be switched at a time, since the valves are mutually interlocked Linear temperature compensation (function 86) The is temperature-compensated for sensitivity. If an additional temperature error occurs during operation, for instance, due to light contamination of the sample chamber, it can be compensated with this function. 86 Lin. temp. comp. MC Aftercompensation of the zero point Aftercompensation of the span Figure 5-67 Linear temperature compensation Operating Instructions, 12/2011, A5E

102 Operation 5.6 Configuration Temperature compensation at the zero point Assuming an average temperature TM, two different correction values can be specified for ranges of increased temperature and decreased temperature. Example: If the zero point changes by +0.3 % (relative) in relation to the difference between 100 % O2 and the start value of the smallest span due to a temperature increase in the sample chamber changes from TM to TM, the value determined by the following formula should be entered under "Δ" for a temperature increase: A factor can be determined for a temperature decrease in the same manner. If only a correction factor is determined, the first value of opposite sign is entered for the second correction value. Temperature compensation in the measured value: The procedure is the same as for the zero point, however, the percentage change refers to the measured value itself. Example: If the measured value changes from 70 % to 69 % with a temperature increase of 4 C, the percentage change is and therefore Δ = 3.55 [%/10 C]. Note If the zero point changes to negative with temperature change, Δ has a positive sign and vice versa. The same applies to a measured value which becomes smaller. 100 Operating Instructions, 12/2011, A5E

103 Operation 5.6 Configuration Error on/off (function 87) With this function, you switch the message for maintenance requests and faults (see Tables "Causes of maintenance requests" and "Causes of error messages") off individually so that there is no entry in the logbook, no message in the status line of the measured value display, and no external signal sent. 87 Error On/Off MC S1 Parameter memory S2 S3 S4 External fault continue Figure 5-68 Switching errors on and off Error messages which do not apply to this analyzer are identified by the absence of text following the fault number PROFIBUS configuration (function 90) This function can only be called if the device contains additional PROFIBUS electronics (add-on board). This function is used to set the PROFIBUS parameters. 90 PROFIBUS config. O 2 Address :126: TAG : OXYMATSIXTYONE Ident number : 1: Relay on PB :off: Software vers: Boot software: Figure 5-69 Configuring PROFIBUS Operating Instructions, 12/2011, A5E

104 Operation 5.6 Configuration You can set the following specific PROFIBUS parameters: Address (PROFIBUS station address): The address can be set from 0 to 126. Under TAG, you can display the tag assigned to a device in the ELAN network (or the first 16 characters thereof). The configuration behavior of the device is configured with the "Ident number" (softkey 2). Parameters 0, 1 and 3 can be selected and have the following meaning: Parameter Meaning 0 Only the PROFILE ID number is positively acknowledged 1 Only the device-specific ID number is positively acknowledged 3 Only the PROFILE ID number for multivariable devices (complex analyzers) is positively acknowledged. Note In order to work with the provided GSD and DD, the value 1 must be entered for 'Ident number'. Relay by PB. The 8 relays of the additional electronics (add-on board) can be controlled over PROFIBUS using this. To allow activation, none of these relays must be occupied by a device-internal function. Note The parameter 'Relay by PB' is only available with software version and higher of the PROFIBUS additional electronics (add-on board). 102 Operating Instructions, 12/2011, A5E

105 Maintenance and servicing Safety instructions WARNING Work on an open device Disconnect the gas and power supply beforeopening the device. Only carry out adjustments using appropriate tools, for example, to avoid short-circuits on the electronic PCBs. Leaks in the gas channel caused by incorrect installation or calibration may result in the release of gas, which in turn could result in injury to personnel (e.g. poisoning symptoms ) as well as damage to the equipment itself (e.g. danger of corrosion). Maintenance The device must be subjected to annual maintenance to verify its electrical safety and correct operation, in particular the tightness of the sample gas channel (containment system). The operator can extend the maintenance interval in individual cases if no negative effects are expected with respect to chemical corrosion to the seals that come in contact with the sample gas. To allow maintenance work, the top cover can be removed and the front panel swung forwards. If maintenance work is interrupted for more than two hours, the analyzer must be closed again. Service All modules within the housing can be replaced in the event of a defect. Repairs to these modules are not envisaged. Operating Instructions, 12/2011, A5E

106 Appendix 6.2 Analyzer section Design of the analyzer section Analyzer section The analyzer section consists of the functional parts magnetic circuit, sample chamber and the measuring head. 1 Measuring head 10, 17 Coil 2 Restrictor plate 11 Mounting screws 3 O-ring measuring head 12 Bottom part of casing 4 Pressure sensor 13 Sample chamber 5 Electrical terminal board 14 O-ring sample chamber 6, 9 Retaining plate 15 Top part of casing 7 Cut strip-wound core 8 Tension spring 16 Reference gas connection 104 Operating Instructions, 12/2011, A5E

107 Appendix Magnet circuit A magnetic pole shoe is glued into each casing section. The cut strip-wound core placed upon it is held down by a tension spring. This method deflects the forces of the magnetostriction away from the sample chamber. Sample chamber The sample chamber consists of a 1-mm thick center plate in which the sample gas channel is punched, and two 0.3-mm thick cover plates, which contain the openings for the supply of the sample gas and the reference gas. Since the sample gas only comes into contact with the chamber plates, the can be used for numerous combinations of sample gas. The other channels of the measuring system are purged by the reference gas. In the fully-assembled analyzer section, the sample chamber is installed between the two casing sections. Measuring head The microflow sensor of the measuring circuit is located in the measuring head. This is installed in a thermostated aluminum block. The strong magnetic field required to produce a sufficient measurement effect causes interference in the microflow sensor. The aluminum block with the preamp electronics are therefore shielded to eliminate this effect. This screen is composed of Screen cup and Restrictor plate This includes restrictors, the function of which is described in section 2.5. Both parts are made of a material with high permeability. Reference gas channel The reference gas line is a restrictor, which decreases the incoming reference gas pressure to allow a continuous flow of 5 to 10 ml/min. The reference gas line is installed and removed as follows: 1. Loosen the reference gas line at the nozzle and on the analyzer section. 2. Remove the reference gas line. To install, carry out the above steps in reverse order. CAUTION Clogged reference gas channel It is important to ensure that no liquid or dust can enter the connection nozzles or the reference gas line! The measurement function may deteriorate or the device may even fail as a result! See also Principle of operation (Page 16) Operating Instructions, 12/2011, A5E

108 Appendix Disassembling the analyzer section Removing the measuring head Proceed as follows for this: 1. Pull out the measuring head connector cable out of its socket. 2. Loosen socket screws. Now you can remove the measuring head. To install, carry out the above steps in reverse order. It is important here to ensure that all O- rings are re-inserted! In additional, the screen cup should never be removed from the measuring head! Cleaning the sample chamber The sample chamber is not particularly susceptible to faults. If condensation passes through the analyzer as a result of a fault in the gas conditioning, although there is a temporary fault in the measurement (highly oscillating values are displayed), the device is ready for measurements again once the sample chamber has dried out. However, one of the inlets for the reference gas may become clogged and measurement may fail if there is extremely high contamination. This will be apparent from extremely strong fluctuations in the display of measured values. If such situations, you need to clean the sample chamber as follows: 1. Remove the measuring head (as described in the section Removing the measuring head. 2. Blow compressed gas into the sample chamber to clean it. The compressed air passes through the sample gas outlet and through the reference gas channels in the upper part of the casing. You can also flush the sample chamber with trichloroethylene or alcohol.. In such situations, you need to dry it afterwards with a stream of dry air. 3. Install the measuring head again. If the cleaning procedure described above does not produce the desired result, the sample chamber must be completely removed and cleaned in an ultrasonic bath. If this measure does not succeed, you may need to replace the sample chamber. 106 Operating Instructions, 12/2011, A5E

109 Appendix Removing the analyzer section Proceed as follows for this: 1. Pull out the measuring head connector cable out of its socket on the magnetic field terminal board. 2. Remove the reference gas inlet hose from the analyzer section. 3. Disconnect the hose at a suitable location. 4. Remove the analyzer section together with the retaining plate and lift both out of the analyzer. 5. Remove the analyzer section from the retaining plate. 6. Remove the sample gas lines from the analyzer section. Removing the sample chamber Proceed as follows for this: 1. Remove the measuring head (as described in the section Removing the measuring head. 2. Insert a suitable tool (e.g. screwdriver) between the retaining plate and the cut stripwound core (U core) and pry out the retaining plate until the tension spring is released. 3. Remove cut strip-wound core and retaining plate. 4. Loosen the four mounting screws and pull the two parts of the casing apart. The sample chamber is now accessible and can be removed. To install, carry out the above steps in reverse order. It is important to note the following in this regard: Check all O-rings to ensure they are OK, and replace them if they are damaged. Tighten the mounting screws diagonally opposed with a torque of 6 Nm. Calibration Each time a measuring head is replaced or the analyzer section reassembled, you need to recalibrate the device. This procedure is described in section Calibration (Page 50). Leak test A leak test must be carried out following every maintenance measure that affects the analyzer section or the gas channel. This procedure is described in section Sealing (Page 35). If the device fails the leak test, you must replace all seals and hoses or pipes. Operating Instructions, 12/2011, A5E

110 Appendix Removing the sample gas restrictor If the sample gas restrictor is clogged from condensate and therefore needs to be cleaned, or if it a hindrance to the measurement task for other reasons (e.g. due to the use of with gas analyzers of the type ULTRAMAT 6 in certain measuring configuration ), you must remove the restrictor. If there is no a flow indicator (optional) in the device, the sample gas restrictor is located in the sample gas hose between the pipe inlet nozzle and the analyzer section. If there is a flow indicator, the sample gas restrictor is located between it and the analyzer section. The restrictor is secured with a hose clamp. Remove the restrictor as follows: 1. Loosen the hose section in which the restrictor is located. 2. Remove the hose clamp over the restrictor. 3. Use a suitable object (stick, etc.) to push the restrictor out of the hose. 6.3 Replacement of motherboard and add-on board WARNING Dangerous contact voltage You need to open the enclosure to do this work. This makes live parts are accessible, which may cause death or injury due to electric shock when touched. For this reason, you must always disconnect the device from the mains before replacing the board! Replacing the motherboard To do this, proceed as follows: 1. Disconnect the device from the mains. 2. Loosen the screws on the cover of the housing and remove it. 3. Remove the data plug from the rear of the device. 4. Unscrew the three M3 screws located between the plugs. 5. Pullout the plugs of the ribbon cables from the motherboard. 6. Remove the motherboard from the device. 108 Operating Instructions, 12/2011, A5E

111 Appendix Removing the add-on board The procedure is the same as for the motherboard. In contrast to the motherboard, the addon board is only attached to the back of the housing with two screws. Mounting Proceed in reverse order to install the both board. 6.4 Replacing fuses WARNING Dangerous contact voltage You need to open the enclosure to do this work. This makes live parts are accessible, which may cause death or injury due to electric shock when touched. For this reason, you must always disconnect the device from the mains before replacing the board! Improper handling The fuses may be only be replaced by trained or instructed personnel! You may only use fuses of the same type! The device is protected by multiple fuses, the values of which depend on the device model (e.g. supply voltage, heating, etc.): Power Fuse ratings 200 to 240 V 0.63 T/ to 120 V 1 T/250 Fuse ratings in Ampere Fuses F3, F4 These fuses are located in a drawer of the mains connection box. To replace the fuses, use a suitable tool (e.g. a screwdriver) to pry them out and removed them. Operating Instructions, 12/2011, A5E

112 Appendix 6.5 Cleaning the device User Interface The front panel is washable. We recommend using a damp sponge or cloth containing a mild detergent for this. Yu should only apply slight pressure when cleaning, especially in the display area, to avoid damaging the thin membrane. In addition, ensure no water penetrates the interior of the device during cleaning. Interior If necessary, you can gently remove dust and dirt from the interior using a compressed air gun. 6.6 Maintenance requests and fault messages The device is able to detect functional irregularities. These appear, depending on the severity, as either 'Maintenance request' or 'Fault' in the status line of the display. At the same time, they are recorded in the logbook (function 3) and can also be called up there. Pressing the button next to the corresponding log entry acknowledges it. It will appear again, however, if you do not eliminate the cause. Each new message is written to the next free space in the logbook. A total of 32 storage spaces are available, which means that the oldest of 32 log entries is overwritten by a new entry. A power failure deletes all log entries. You can disable the log or delete the messages contained in it using function 60. The display of messages is especially distracting during testing. They can be disabled under the function 87. You should not do this during normal operation, since you need to be able to detect any faults that may occur. Maintenance requests If there are indications of changes in internal device parameters, "Maintenance request" appears in the status line of the display. Changes of this type do not affect the measurement capability of the device or affect it only minimally the first time they appear. In order to continue to guarantee the measuring capability, however, it may be necessary to carry out remedial measures. If the relay output of the device was configured accordingly (see also section 5, Function 71), external signaling may also be performed. 110 Operating Instructions, 12/2011, A5E

113 Appendix Maintenance requests The following error messages result in a maintenance request (output in the display) and are signaled externally if a corresponding relay has been configured using function 71. Function 87 can be used to switch off (disable) each maintenance request individually. Each maintenance requests labeled with "Q" in the left column of the following table must be acknowledged. No. Message Possible causes Remedy Remarks W1 Calibration Calibration gas was changed Repeat calibration Calibration tolerance, see also Q tolerance Drift characteristics Check that drift is normal function 78; exceeded Drift of device according to technical specifications: Zero point: 1% of FSV/week, Span: >1% of FSV/week W2 Q W3 Q W4 Q W6 Q W7 Q Signal span to Reference gas contains too high with zero much oxygen point adjustment Zero gas contains too much oxygen Signal voltage too low with span adjustment Zero gas contains too little oxygen Reference gas flow is too low An incorrect measuring range has been selected for the calibration Check reference gas Check zero gas Check calibration gas Check reference gas flow and correct if necessary Select the correct measuring range Zero gas and reference gas should be identical Set clock The device was switched off Reenter the date and time See function 58 Temperature of LCD is too high or too low Temperature of analyzer section Ambient temperature outside tolerances specified in the technical specifications (5 to 45 C) Ambient temperature too high ( 45 C) Measuring head temperature too high ( 78 C) (only applies to non-heated model) With a heated sample chamber: selected setpoint temperature is too low or heating is switched off. Message W7 appears until the new setpoint temperature has been reached Make sure that the ambient temperature is in the range from 5 to 45 C Check ambient temperature (max. 45 C), especially with built-in analyzers Contact service department No error! Wait until the analyzer section has cooled down to the new setpoint temperature Operating Instructions, 12/2011, A5E

114 Appendix No. Message Possible causes Remedy Remarks W8 Q W9 W10 Temperature of measuring head outside tolerance External maintenance request AUTOCAL/Chec k error More than ±3 C deviation from the setpoint temperature (see also S7) If temperature remains constant: no need for action; otherwise: contact service department Signal from external source Check Function 72 must be configured accordingly Tolerances that are exceeded in AUTOCAL/Check or false sample gas (assignment to the measuring range is wrong) Perform AUTOCAL again This message disappears only when the AUTOCAL has been successfully completed. Causes of maintenance requests 112 Operating Instructions, 12/2011, A5E

115 Appendix Faults The following faults result in a fault message (output in the display) and are signaled externally if a corresponding relay has been configured using function 71. The measurement capability of the device is restricted if these messages appear. Immediate remedial measures should always be carried out here by qualified maintenance personnel. Function 87 can be used to switch off (disable) each fault message individually. Each maintenance requests labeled with "Q" in the left column of the following table must be acknowledged. No. Message Possible causes Remedy S1 Q Parameter memory test failed EEPROM contains incorrect or incomplete data in the working range 1. Execute RESET or switch the device off and on again. If the error message S1 appears again: 2. Load user data (function 75) 3. contact service department, Make sure you leave the device in operation in order to assist the fault diagnostics of the service staff! S2 Q S3 Q Magnetic field supply faulty Microflow sensor faulty Ribbon cable connection interrupted Motherboard faulty One half of the grid has been destroyed Check connection contact service department Replace measuring head or contact service department S4 External fault message Signal from external source Check: Function 72 must be configured accordingly S5 Q S7 Q Temperature of analyzer section is too high or too low Temperature of measuring head outside tolerance Ambient temperature outside tolerances specified in the technical specifications (5 to 45 C) Measuring head temperature too high (>80 C) or too low (<10 C) Temperature sensor faulty: Temperature rises above setpoint temperature More than ±5 C deviation from the setpoint temperature (75 C) Make sure that the ambient temperature is in the permissible range from 5 to 45 C Perform restart (RESET); if this is not successful: contact service department Replace measuring head or contact service department Operating Instructions, 12/2011, A5E

116 Appendix No. Message Possible causes Remedy S8 Q S9 Q S10 Q S11 S12 Q S13 Q S14 S 15 Q Signal of selected pressure sensor outside tolerance Signal too high Sample gas blocked at outlet (> hpa with internal pressure sensor or > hpa with external) or system pressure too high Sample gas pressure too low (< 500 hpa) Sample gas pressure > hpa or O2 concentration in range to hpa too high Caution The internal pressure sensor may be destroyed if the system pressure exceeds hpa! 1. Perform a suitable action to reduce the flow resistance at the device inlet until the sample gas is back within the tolerance limits 2. Regulate the system pressure accordingly 3 Check for leaks (see section Preparation for commissioning), If leak is found: contact service department Set system pressure > 500 hpa Reduce pressure or O2 concentration or contact service department RAM check RAM PROM Replace motherboard or contact service department Reference gas supply failed Mains power supply Hardware / line frequency Measured value greater than operating full-scale value (+ 5 %) Calibration aborted Reference gas line leaks, is interrupted or blocked Reference gas source is empty Mains voltage outside tolerance limits Mains frequency outside tolerance limits Crystal or external ADC defective Sample gas pressure exceeds the pressure correction range of or hpa Incorrect calibration of the measuring range Fault if the device is in AUTOCAL mode Fault in calibration via digital input Check reference gas flow (see section 4.2 Preparation for commissioning) Connect new reference gas source Line voltage must be within the specified limits specified by the rating plate Connect power supply stabilizer Replace motherboard Check the sample gas pressure and possibly reduce it or switch to an external pressure sensor with an appropriate measuring range Repeat calibration and possibly check the sample test Remedy the cause S16 Sample gas flow is too low Ensure sufficient flow Causes of fault messages 114 Operating Instructions, 12/2011, A5E

117 Appendix Spare parts list General information This spare parts list corresponds to the technical status of February The rating plate shows the year of construction of the gas analyzer (coded in the production no.). An order for spare parts must contain the following information: Quantity Designation of the spare part Order no. of the spare part Device name, order number, and production no. of the gas analyzer for which the spare part is intended Example for ordering 2 measuring heads C79000-A3460-B525 for, MLFB 7MB2001-0FA00-0AA0, Prod. no. N1-JD-352 Operating Instructions, 12/2011, A5E

118 Appendix Overview of the modules O4 O3 O2 O1 O1 O2 O3 O4 Figure 7-1 Analyzer section Electronics Sample gas channel Reference gas channel modules 116 Operating Instructions, 12/2011, A5E

119 Appendix 7.2 Analyzer section Table 7-1 Part no. Designation Order no. Remarks O1.1 Analyzer section complete, material no C79451-A3460-B31 O1.2 Measuring head C79451-A3460-B525 O1.2.1 O-ring C Z100-A32 1 item O1.3 Sample chamber, material no C A3277-B535 O1.4 Magnet terminal board C79451-A3474-B606 O1.5 O-ring, FPM (Viton) C71121-Z100-A159 1 item, analyzer section Operating Instructions, 12/2011, A5E

120 Appendix 7.3 Electronics Table 7-2 Part no. Designation Order no. Remarks O2.1 Motherboard C79451-A3480-D501 C79451-A3480-D502 C79451-A3480-D503 C79451-A3480-D504 C79451-A3480-D505 O2.1.1 Firmware (FlashPROM) C79451-A3460-S501 C79451-A3460-S502 C79451-A3460-S503 C79451-A3460-S504 C79451-A3460-S505 O2.2 Add-on board C79451-A3480-D511 A5E A5E A5E O2.3 Plug-in filter W75041-E5602-K2 O2.4 G--type fuse W79054-L1010-T630 W79054-L1011-T100 O2.5 LC display W75025-B5001-B1 O2.6 Adapter board, LCD/keyboard C79451-A3474-B605 Motherboard and firmware German, Motherboard and firmware English Motherboard and firmware French Motherboard and firmware Spanish v Italian German English French Spanish Italian Relay PROFIBUS PA PROFIBUS DP Firmware update PROFIBUS 200 V to 240 V, T 0.63 A/250 V 100 V to 120 V, T 1 A/250 V O2.7 Front panel A5E With membrane keyboard, Electronics 118 Operating Instructions, 12/2011, A5E

121 Appendix 7.4 Gas channel Figure 7-2 Sample gas channel, with hoses Operating Instructions, 12/2011, A5E

122 Appendix Figure 7-3 Gas connections Table 7-3 Part no. Designation Order no. Remarks O3.1 Restrictor C79451-A3480-C10 Gas channel hose O3.1 Attenuator A5E Attenuator with hose O3.2 O-ring, FPM (Viton) C74121-Z100-A6 1 item O3.4 Flow meter C79402-Z560-T1 O3.5 Pressure switch C79302-Z1210-A2 120 Operating Instructions, 12/2011, A5E

123 Appendix Figure 7-4 Reference gas channel for external reference gas supply with 2000 to 4000 hpa Operating Instructions, 12/2011, A5E

124 Appendix Figure 7-5 Reference gas channel for internal reference gas supply with ambient pressure +/- 50 hpa Table 7-4 Part no. Designation Order no. Remarks O4.1 Nozzle, complete C79451-A3480-B1 Ø 6 mm, hpa Nozzle, complete C79451-A3480-B2 1/4", hpa O4.3 Capillary C79451-A3480-D hpa O4.4 Reference gas supply A5E Pump module complete 122 Operating Instructions, 12/2011, A5E

125 Appendix Technical specifications General technical specifications Table 8-1 Technical specifications general technical specifications General technical specifications Measuring ranges 4, internally and externally switchable; manual and automatic range switching is possible Smallest possible measuring span 3) 2 vol. % or 5 vol. % O2 Largest possible span 0 to 100% vol. O2 Measuring ranges with suppressed zero point Any zero point can be implemented within vol.% O2 provided that a suitable reference gas is used (see also Reference gases (Page 126)) EMC interference immunity (electromagnetic compatibility) In accordance with standard requirements of NAMUR NE21 (08/98), EN , EN Degree of protection IP 20 according to EN Electrical safety According to EN , overvoltage category III Position of use (analyzer) Front panel vertical Dimensions (analyzer) See Section "Dimensional drawing" Weight (analyzer) Approx. 13 kg Table 8-2 Technical specifications power supply Power supply Auxiliary power (see rating plate) 100 to 120 V AC (rated range of use 90 V to 132 V), 48 to 63 Hz or 200 to 240 V AC (rated range of use 180 V to 264 V), 48 to 63 Hz Approx. 37 VA Power consumption (analyzer) Fuse ratings V 1T/ V 0.63T/250 Operating Instructions, 12/2011, A5E

126 Appendix Table 8-3 Technical specifications gas inlet conditions Gas inlet conditions Permissible sample gas pressure 800 to hpa absolute (with external reference gas supply), atm. pressure range (with built-in pump) Sample gas flow 18 to 60 l/h (0.3 to 1 l/min) Sample gas temperature 0 to 50 C Sample gas moisture content < 90 % RH 1) Table 8-4 Technical specifications time response Time response Warmup time At room temperature: < 30 min 2) Display response time (t90) Damping (electronic time constant) Dead time (purging time of the gas channel in the device at 1 l/min) Time for signal processing in the device 3.5 s 0 to 100 s, can be configured Approx. 0.5 to 2.5 s, depending on model < 1 s Table 8-5 Technical specifications pressure correction range Pressure correction range Pressure sensor 500 to hpa (abs.) Table 8-6 Technical specifications measuring characteristics Measuring characteristics Output signal variation Zero point drift Measured value drift Repeatability Linearity deviation < ± 0.75 % of the smallest possible measuring range according to rating plate, with electronic time constant of 1 s (corresponds to ± 0.25% at 2 σ) < ± 0.5 %/month of respective span < ± 0.5 %/month of respective span < ±1% of respective span < ±1% of respective span 124 Operating Instructions, 12/2011, A5E

127 Appendix Table 8-7 Technical specifications influencing variables Influencing variables 3) Ambient temperature Sample gas pressure Associated gases Sample gas flow Power supply < 0.5 %/10 K relative to smallest possible span according to rating plate With disabled pressure compensation: < 2 % of the current measuring range / 1 % pressure change With enabled pressure compensation: < 0.2 % of the current measuring range / 1 % pressure change Deviation from zero point corresponding to paramagnetic or diamagnetic deviation of accompanying gas (see table 3.2) < 1 % of smallest possible span according to rating plate with 0.1 l change in flow within the permissible flow range < 0.1 % of the current measuring range with rated voltage ± 10% Table 8-8 Technical specifications electric inputs and outputs Electric inputs and outputs Analog output Relay outputs Analog inputs Digital inputs Serial interface Options 0/2/4 to 20 ma, isolated; Max. load 750 Ω 6, with changeover contacts, can be freely configured, e.g. for measuring range identification; Max. load: 24 V AC/DC / 1 A floating 2, designed for 0/2/4 to 20 ma for external pressure sensor and/or correction of associated gas influence (cross-interference correction) 6, designed for 24 V, isolated, freely configurable, e.g. for measuring range switchover RS485 Supplementary electronics with 8 additional digital inputs and 8 additional relay outputs, e.g. for triggering automatic calibration; supplementary electronics for PROFIBUS-PA and PROFIBUS-DP Operating Instructions, 12/2011, A5E

128 Appendix Table 8-9 Technical specifications climatic conditions Climatic conditions Permissible ambient temperature Permissible humidity Storage and transport: -40 to +70 C, operation: +5 to +45 C <90 % RH 1) as annual mean, during storage and transport 4) 1) RH: relative humidity 2) Maximum accuracy is achieved after approximately 3 hours 3) Relative to sample gas pressure hpa (absolute), sample gas flow 0.5 l and ambient temperature 25 4) Dew point low limit may not be violated! 5) The error of the calibration gas must also be taken into account * Based on DIN EN / IEC Reference gases Table 8-10 Reference gases for Measuring range 0 to 100 vol. % O2 N2, 4.6 to 100 vol. % O2 (suppressed zero point with measuring range full-scale value 100 vol. % O2) Recommended reference gas O2 Reference gas connection pressure to hpa above sample gas pressure (max hpa absolute) Remarks The reference gas flow is set automatically to 5 to 10 ml/min Around 21 % O2 (suppressed zero with 21 vol. % O2 within the span) Air Atmospheric pressure with internal reference gas pump 126 Operating Instructions, 12/2011, A5E

129 Appendix 8.3 Zero point error Table 8-11 Zero point errors of different accompanying gases Associated gas (concentration 100 vol. %) Zero point deviation in vol. % absolute Associated gas (concentration 100 vol. %) Zero point deviation in vol. % absolute Organic gases Inert gases Ethyne (acetylene) C2H Argon Ar butadiene C4H Helium He butadiene C4H Krypton Kr n-butane C4H Neon Ne Isobutane C4H Xenon Xe butene C4H Inorganic gases Isobutene C4H Ammonia NH Dichlorodifluoromethane CCl2F Hydrogen bromide HBr (R12) Ethanoic acid CH3COOH Chlorine Cl n-heptane C7H Hydrogen chloride HCl n-hexane C6H Dinitrogen monoxide N2O Cyclo-hexane C6H Hydrogen fluoride HF Methane CH Hydrogen iodide HI Methanol CH3OH Carbon dioxide CO n-octane C8H Carbon monoxide CO n-pentane C5H Oxygen O Isopentane C5H Nitric oxide NO Propane C3H8-0,87 Nitrogen N Propylene C3H Nitrogen dioxide NO Trichlorofluoromethane (R11) CCl3F Sulfur dioxide SO Vinyl chloride C2H3Cl Sulfur hexafluoride SF Vinyl fluoride C2H3F Hydrogen sulfide H2S vinylidene chloride C2H2Cl Water H2O Hydrogen H Zero point error due to diamagnetism or paramagnetism of some residual gases with nitrogen as the reference gas at 60 C and hpa absolute (according to IEC 1207/3) Conversion to other temperatures For this, multiply the deviations from the zero point listed in Table 3.2 by a correction factor (k): For diamagnetic* gases: k = 333 K / θ [ C] K) For paramagnetic gases: k = [333 K / θ ([ C) K)] 2 * All diamagnetic gases have a negative deviation from zero point Operating Instructions, 12/2011, A5E

130 Appendix 8.4 Materials used in the sample gas channel Standard Gas channel With hoses 19" rack unit Procedure Hose FPM (Viton) Sample chamber Nozzles for sample chamber Restrictor PTFE (Teflon) O-rings FPM (Viton) Hose coupling Polyamide 6 Options Flow indicator Measuring tube Duran glass Float-type meters Duran glass Suspension boundary PTFE (Teflon) Angle pieces FPM (Viton) Sample gas Membrane FPM (Viton) pressure switch Enclosure PA 6.3 T 128 Operating Instructions, 12/2011, A5E

131 Appendix Dimension drawings Dimension drawings ,5 384,5 Figure 9-1 Dimensions for preparing installation (in mm) (front view and plan view) Operating Instructions, 12/2011, A5E

132 Appendix??? Figure 9-2 Dimensions for preparing installation (in mm) (front view and plan view) 130 Operating Instructions, 12/2011, A5E

133 Appendix Appendix A A.1 EC Declaration of Conformity Operating Instructions, 12/2011, A5E

134 Appendix A.1 EC Declaration of Conformity 132 Operating Instructions, 12/2011, A5E

135 Appendix A.2 Return delivery A.2 Return delivery The analyzer or replacement parts should be returned in their original packaging material. If the original packing material is no longer available, wrap the analyzer in plastic foil and pack in a sufficiently large box lined with additional padding material (wood shavings, foam rubber, etc.). If you use wood shavings, the padding should be at least 15 cm thick on all sides. When shipping overseas, the analyzer must be additionally sealed air-tight in polyethylene foil at least 0.2 mm thick and a drying agent (e.g. silica gel) should be added. In addition, the transport container should be lined with a layer of kraft paper. Photocopy the return delivery form, fill it in and enclose it with the returned device. In case of guarantee claim, please enclose your guarantee card. Return delivery addresses Spare parts service Send your orders for spare parts to the following address: SIEMENS SPA CSC Tel.: (00333) Fax: (00333) , chemin de la Sandlach F Haguenau, France - DP order form recipient: 0011E Repairs To enable us to quickly identify and correct faults, return the analyzers to the following address (applicable until further notice): SIEMENS SPA CSC Tel.: (00333) Fax: (00333) , chemin de la Sandlach F Haguenau, France - DP order form recipient: 0011E Operating Instructions, 12/2011, A5E

136 Appendix A.2 Return delivery Customer name Person responsible Delivery address Phone Fax Return address (if different from address above) Customer (original) Order number Device name MLFB no. Production no. Description of returned part Fault description Process data at location of use Operating temperature Operating pressure Sample gas composition Operating hours/ operating date Service report RH no.: Date received: Date returned: Technician: 134 Operating Instructions, 12/2011, A5E

137 ESD Directives B B.1 ESD guidelines Definition of ESD All electronic modules are equipped with large-scale integrated ICs or components. Due to their design, these electronic elements are highly sensitive to overvoltage, and thus to any electrostatic discharge. The electrostatic sensitive components/modules are commonly referred to as ESD devices. This is also the international abbreviation for such devices. ESD modules are identified by the following symbol: CAUTION ESD devices can be destroyed by voltages well below the threshold of human perception. These static voltages develop when you touch a component or electrical connection of a device without having drained the static charges present on your body. The electrostatic discharge current may lead to latent failure of a module, that is, this damage may not be significant immediately, but in operation may cause malfunction. Operating Instructions, 12/2011, A5E